Aseptic filling apparatus and method of decontaminating the same

ABSTRACT

In an aseptic filling apparatus, a CIP of the content filling station is performed after rotation of a wheel in the content filling station is stopped, a COP or SOP of the content filling station is performed while the wheel in the content filling station is rotating immediately after the CIP is completed, an SIP of the content filling station is performed with rotation of the wheel in the content filling station being stopped immediately after the COP or SOP is completed, and one or both of the COP and SOP of the other stations is performed in a predetermined order while wheels in the other stations are rotating in a period from the start of the CIP to the end of the SIP.

CROSS REFERENCE TO RELATED APPLICATION

This application is a division of U.S. application Ser. No. 15/745,819,filed Jan. 18, 2018, which in turn is the National Stage entry ofInternational Application No. PCT/JP2016/077249, filed Sep. 15, 2016,which designated the United States, the entireties of which areincorporated herein by reference.

FIELD OF THE INVENTION

The present invention relates to an aseptic filling apparatus and amethod of decontaminating the aseptic filling apparatus by cleaning andsterilization.

BACKGROUND OF THE INVENTION

An aseptic filling apparatus includes a wheel train that conveys acontainer such as a bottle in one direction, and a container sterilizingstation, a content filling station and a container sealing station arearranged from the upstream side to the downstream side of the flow ofthe container fed by rotation of the wheels in the wheel train.

In the container sterilizing station, there is arranged a nozzle thatblasts mist of a hydrogen peroxide solution, which is a sterilizer, tothe container moving around a wheel. The content filling station isconfigured as a filler in which a content filling nozzle rotates arounda wheel. The container sealing station is configured as a capper thatscrews a cap onto a mouth portion of the bottle.

In addition, there are provided chambers that cover the wheel train andportions from the container sterilizing station to the container sealingstation (see Patent Literatures 1 and 2, for example).

In the content filling station in the aseptic filling apparatus, thereare provided a large number of filling nozzles that are arranged atregular intervals along the circumference of a predetermined wheel tofill a large number of bottles with a drink, which is a content, at highrate.

All the filling nozzles rotate at high speed along with the wheel tofill the bottles traveling in synchronization with the filling nozzleswith a fixed amount of drink.

The drink is supplied from a preparation apparatus therefor to thefilling nozzles in the content filling station through drink supplypiping. The drink supply piping is subjected to a CIP (Cleaning inPlace) to remove any remainder or foreign matters and is furthersubjected to an SIP (Sterilizing in Place) to be sterilized at regularintervals or when to change the kind of the drink (see PatentLiteratures 3, 4 and 5, for example).

The CIP is performed by flowing a cleaning liquid through a flow pathfrom the interior of the drink supply piping to the filling nozzles inthe filler, the cleaning liquid containing water and an alkali agentsuch as sodium hydroxide or potassium hydroxide or an acidic agent suchas nitric acid as an additive. In this way, any remainder of thepreviously used drink or the like adhering to the interior of the drinksupply piping is removed (see Patent Literatures 3, 4 and 5, forexample).

The SIP is performed by flowing a vapor, hot water or the like throughthe piping cleaned by the CIP, and the interior of the drink supplypiping is sterilized by being heated by the vapor, hot water or the like(see the paragraph [0003] in Patent Literature 5).

Specifically, the CIP and SIP of the interior of the drink supply pipingis performed as described below.

Since a liquid needs to be circulated in the drink supply piping and awaste liquid needs to be collected, a cup is placed over the nozzlemouth of each filling nozzle at rest. The cups are arranged so as to berotatable with the filling nozzles. A manifold that rotates with thefilling nozzles and the cups is provided in advance around a pivotaround which the filling nozzles rotate. The cup is coupled to themanifold by a pipe, and the manifold is connected to a cleaning-liquidreservoir tank and a pump by a pipe that can be opened and closed. Thecleaning-liquid reservoir tank and the pump are fixed to a machinecasing or chamber of the content filling station.

When performing the CIP or SIP, rotation of the filling nozzles and themanifold is stopped, the cups are automatically placed on the nozzlemouths to establish a communication between the cups and the manifold,and the manifold and the cleaning-liquid reservoir tank are connected toeach other by the pipe.

Then, the cleaning liquid flows from the cleaning-liquid reservoir tankinto the drink supply piping, further flows into the filling nozzles andthen into the manifold through the nozzle mouths and the cups and thuscirculates for a predetermined time. In this way, the CIP of theinterior of the drink supply piping and the filling nozzles isperformed.

When performing the SIP, hot water or the like is flowed into the drinksupply piping and the filling nozzles as in the case of the CIPdescribed above. In this way, the interior of the drink supply pipingand the filling nozzles is sterilized.

On the other hand, in the chamber, a COP (Cleaning out of Place) and anSOP (Sterilizing out of Place) are performed to decontaminate the outersurface of the content filling station or the like and the inner wall ofthe chamber (see Patent Literatures 6, 7, 8 and 9, for example).

To perform the COP and the SOP, various kinds of injection nozzles arearranged in the chamber at different locations. When performing the COPand the SOP, a chemical agent, such as an alkali cleaner, a peraceticacid cleaner or a hydrogen peroxide solution, aseptic water and the likeare successively sprayed or injected like a shower in the chamber. Themist, shower or the like of the chemical agent or water cleans andsterilizes the inner wall of the chamber and the surface of equipmentsuch as the filler.

As described above, after the CIP, SIP, COP and SOP of the asepticfilling apparatus are performed, the aseptic filling apparatus startsfilling a bottle with a drink, the sterilized bottle is filled in anaseptic environment, and an aseptic bottled drink is produced.

CITATION LIST Patent Literature

-   Patent Literature 1: Japanese Patent Laid-Open No. 2001-39414-   Patent Literature 2: Japanese Patent Laid-Open No. 2006-111295-   Patent Literature 3: Japanese Patent Laid-Open No. 2007-331801-   Patent Literature 4: Japanese Patent Laid-Open No. 2000-153245-   Patent Literature 5: Japanese Patent Laid-Open No. 2007-22600-   Patent Literature 6: Japanese Patent No. 3315918-   Patent Literature 7: Japanese Patent Laid-Open No. 2004-299723-   Patent Literature 8: Japanese Patent Laid-Open No. 2010-189034-   Patent Literature 9: Japanese Patent No. 5582213

SUMMARY OF THE INVENTION Technical Problem

As described above, when the CIP and SIP of the interior of the drinksupply piping are performed, the manifold and the cleaning-liquid supplysource are connected by a pipe, and thus, rotation of the wheel in thecontent filling station is stopped to stop rotation of the fillingnozzles or the like. In addition, since the wheels of the conventionalwheel train are always engaged for power transmission between thecontainer sterilizing station, the content filling station and thecontainer sealing station, if the wheel in the content filling stationis stopped, the wheels in the container sterilizing station and thecontainer sealing station are also stopped.

Thus, as shown in FIG. 11 , when the CIP or SIP of the drink supplypiping is performed, the COP and the SOP are set in the standby state,and the COP and the SOP are started after the CIP or SIP is completed.

This is because, if the COP or SOP of the interior of the chamber isperformed at the same time as the CIP or SIP, since the wheels arestopped, the cleaning liquid or sterilizing liquid does not spread intoevery corner of the container sterilizing station, the content fillingstation and the container sealing station, and the stations tends to bepoorly cleaned and sterilized.

In particular, the filling nozzles in the content filling station have acomplicated shape and structure, so that even if the COP or SOP isperformed on the content filling station at rest, the filling nozzlestends to be poorly cleaned and sterilized. Since the filling nozzles areused to fill the bottles with a drink, if bacteria or foreign mattersremain on the surface of the filling nozzles, the bacteria or foreignmatters are likely to enter the bottles.

To avoid this, conventionally, the COP or SOP of the interior of thechamber is performed in a state where the filling nozzles or the likeare allowed to rotate after the CIP and SIP of the drink supply pipingis completed, the pipe connecting the manifold and the cleaning-liquidreservoir tank is disconnected, and then all the wheels of the wheeltrain are allowed to rotate.

That is, the cleaning liquid or the like is injected from various kindsof nozzles in the chamber for the content filling station in a statewhere the content filling station is being driven and the fillingnozzles are rotating, so that a spray or shower of the cleaning liquidor the like spreads into every corner of the content filling station, inparticular, every corner of the filling nozzles, and the content fillingstation is appropriately cleaned and sterilized. Similarly, if thecleaning liquid or the like is injected from various kinds of nozzles inthe chamber for the container sterilizing station while the wheel in thecontainer sterilizing station is rotating, a spray or shower of thecleaning liquid or the like spreads into every corner of the containersterilizing station, and the container sterilizing station isappropriately cleaned and sterilized. Furthermore, if the cleaningliquid or the like is injected from various kinds of nozzles in thechamber for the container sealing station while the wheel in thecontainer sealing station is rotating, a spray or shower of the cleaningliquid or the like spreads into every corner of the containersterilizing station, and the container sterilizing station isappropriately cleaned and sterilized.

However, if the COP and the SOP of the interior of the chamber areperformed after the CIP or SIP of the drink supply piping is completed,the downtime (time out of production) of the aseptic filling apparatusis elongated, and the productivity of the bottled drink is reduced.

Now, FIG. 6 shows an example of a decontamination operation such as CIPconventionally performed on the aseptic filling apparatus.

As shown in FIG. 6 , to start manufacture of another kind of bottleddrink after manufacture of a kind of bottled drink is completed, theoperation of the content filling station is stopped to perform the CIPof the drink supply piping when the manufacture of the previous bottleddrink is completed.

After the CIP is completed, operation of the content filling station isstarted, and the SOP (or COP) is performed by successively blastingperacetic acid and aseptic water to the filling nozzles or the like thatare rotating.

When the SOP (or COP) of the content filling station is completed, theoperation of the content filling station is stopped to perform the SIPof the drink supply piping.

On the other hand, during the CIP or SIP of the content filling stationdescribed above, the wheels in the stations other than the contentfilling station, such as the container sealing station, are stopped sothat those stations are at rest, and a spray of a hydrogen peroxidesolution or gas or mist or the like of hydrogen peroxide, or the like isblasted to those stations at rest to perform the SOP (or COP) thereof.

Furthermore, a method in which the SOP is performed between the CIP andthe SIP is also known. The SOP is performed between the CIP and the SIP,because if the cleaning liquid used in the CIP or any waste liquid leaksat the connection between a cup and a nozzle mouth, for example, thewaste liquid or the like can adhere to equipment or the like in thecontent filling station and enter the drink or container during thesubsequent filling operation. The SOP between the SIP and the CIP canwash the waste liquid or the like from the equipment or the like in thecontent filling station, so that the sterilization by the SIP can beperformed in a state where the exterior of the equipment or the like inthe content filling station is kept clean.

Until the SIP is performed after the CIP of the interior of the drinksupply piping is completed, as shown in FIG. 12 , the interior of thepiping is rinsed by water supplied into the drink supply piping from afinal stage of the CIP, thereby removing the waste liquid, the cleaningliquid and the like from the interior of the drink supply piping andcooling the interior of the piping. Supply of water into the piping isthen started, and the temperature of the water is gradually raised to atemperature required for sterilization in the subsequent SIP.

The same SOP (or COP) as the SOP (or COP) of the content filling stationdescribed above is performed on the other stations. In this process, theother stations are being driven as with the content filling station. TheSOP (or COP) is performed stepwise on the other stations being driven ina period from the end of the CIP to the start of the SIP of the contentfilling station.

The SOP (or COP) is performed stepwise because it is difficult toprepare a large amount of peracetic acid or other sterilizer and asepticwater supplied to all the stations at the same time. Thus, afterperacetic acid is supplied stepwise to the stations, aseptic water issupplied stepwise to the stations.

Due to the circumstances described above, the decontamination operationperformed on the aseptic filling apparatus takes about 6 hours in theexample shown in FIG. That is, the downtime of the aseptic fillingapparatus is significantly elongated, the decontamination operation is acause of reduction of the productivity of the bottled drink.

Thus, an object of the present invention is to provide an asepticfilling apparatus and a method of decontaminating the same that cansolve the problems described above.

Solution to Problem

To achieve the object described above, the present invention adopts theconfigurations described below.

Note that reference numerals in parentheses are given to facilitateunderstanding of the present invention and are not intended to limit thescope of the present invention.

Specifically, the invention according to a first aspect of the presentinvention adopts a method of decontaminating an aseptic fillingapparatus, the aseptic filling apparatus comprising various kinds ofstations including a content filling station (6) arranged from anupstream side to a downstream side of a flow of a preform or container(3) fed by rotation of wheels (12, 13, 9, 17 and the like) in a wheeltrain, and each of the various kinds of stations being covered by achamber (20, 21, 56), wherein a CIP (Step S1) of the content fillingstation (6) is performed after rotation of a wheel (9) in the contentfilling station (6) is stopped, a COP or SOP (Step S2) of the contentfilling station (6) is performed while the wheel (9) in the contentfilling station (6) is rotating immediately after the CIP (Step S1) iscompleted, an SIP (Step S3) of the content filling station (6) isperformed with rotation of the wheel (9) in the content filling station(6) being stopped immediately after the COP or SOP (Step S2) iscompleted, and one or both of the COP and SOP (Steps S4, S5, S6, S7) ofthe other stations (5, 7) is performed in a predetermined order whilewheels (12, 13, 17 and the like) in the other stations (5, 7, 53) isrotating in a period from the start of the CIP (Step S1) to the end ofthe SIP (Step S3).

According to a second aspect of the present invention, in the method ofdecontaminating an aseptic filling apparatus according to the firstaspect of the present invention, the SOP (Step S2) of the contentfilling station (6) and the SOP (Step S2) of the other stations (5, 7,53) may be performed stepwise in a period from the start of the SOP(Step S2) to the end of the SIP (Step S3) of the content filling station(6).

According to a third aspect of the present invention, in the method ofdecontaminating an aseptic filling apparatus according to the firstaspect of the present invention, the SOP (Step S2) of the contentfilling station (6) and the SOP (Steps S5, S6, S7) of the other stations(5, 7, 53) may be performed in parallel between the stations (5, 6, 7,53).

According to a fourth aspect of the present invention, in the method ofdecontaminating an aseptic filling apparatus according to the second orthird aspects of the present invention, wherein the SOP may be performedby blasting of a sterilizer and blasting of aseptic water.

The invention according to a fifth aspect of the present inventionadopts a method of decontaminating an aseptic filling apparatus, theaseptic filling apparatus comprising various kinds of stations includinga content filling station (6) arranged from an upstream side to adownstream side of a flow of a preform or container (3) fed by rotationof wheels (12, 13, 9, 17 and the like) in a wheel train, and each of thevarious kinds of stations being covered by a chamber (20, 21, 56),wherein a CIP (Step S1) of the content filling station (6) is performedafter rotation of a wheel (9) in the content filling station (6) isstopped, the temperature of a cleaning liquid is raised to a temperaturerequired for an SIP subsequent to the CIP from an early stage or amiddle of the CIP, the SIP (Step S2) of the content filling station (6)is performed to sterilize the content filling station (6) and thecleaning liquid is removed with rotation of the wheel (9) in the contentfilling station (6) kept stopped, and one or both of a COP and an SOP(Step S3) of the content filling station (6) is performed in apredetermined order while the wheel (9) in the content filling station(6) is rotating immediately after the SIP (Step S2) is completed.

The invention according to a sixth aspect of the present inventionadopts a method of decontaminating an aseptic filling apparatus, theaseptic filling apparatus comprising various kinds of stations includinga content filling station (6) arranged from an upstream side to adownstream side of a flow of a preform or container (3) fed by rotationof wheels (12, 13, 9, 17 and the like) in a wheel train, and each of thevarious kinds of stations being covered by a chamber (20, 21, 56),wherein an SIP (Step S1), which serves also as a CIP, of the contentfilling station (6) is performed after rotation of a wheel (9) in thecontent filling station (6) is stopped, and one or both of a COP and anSOP (Step S2) of the content filling station (6) is performed in apredetermined order while the content filling station (6) is rotatingimmediately after the SIP (Step S1) is completed.

According to a seventh aspect of the present invention, in the method ofdecontaminating an aseptic filling apparatus according to the fifth orsixth aspects of the present invention, the SOP (Step S3) of the contentfilling station (6) and the SOP (Steps S5, S6, S7) of the other stations(5, 7, 53) may be performed stepwise immediately after the SIP (Step S2)of the content filling station (6) is completed.

According to an eighth aspect of the present invention, in the method ofdecontaminating an aseptic filling apparatus according to the fifth orsixth aspects of the present invention, wherein the SOP (Step S3) of thecontent filling station (6) and the SOP (Steps S5, S6, S7) of the otherstations (5, 7, 53) may be performed in parallel with each otherimmediately after the SIP (Step S2) of the content filling station (6)is completed.

According to a ninth aspect of the present invention, in the method ofdecontaminating an aseptic filling apparatus according to the seventh oreighth aspects of the present invention, the SOP may be performed byblasting of hot water or a sterilizer and blasting of aseptic water.

According to a tenth aspect of the present invention, in the method ofdecontaminating an aseptic filling apparatus according to the first,fifth and sixth aspects of the present invention, the SOP (Step S4) ofthe other stations (5, 7, 53) may be performed while the CIP (Step S1)or SIP (Step S3) of the content filling station (6) is being performed,and the SOP (Step S4) may be performed by blasting of gas or mist of asterilizer containing hydrogen peroxide.

According to an eleventh aspect of the present invention, in the methodof decontaminating an aseptic filling apparatus according to the first,fifth and sixth aspects of the present invention, aseptic air may beconstantly blasted to the content filling station (6) in the chamber(21).

According to a twelfth aspect of the present invention, in the method ofdecontaminating an aseptic filling apparatus according to the first,fifth and sixth aspects of the present invention, a clutch that connectsand disconnects transmission of power between wheels may be providedbetween the wheel (9) in the content filling station (6) and anotherwheel (12, 13, 17 or the like), and the clutch may be disconnected tostop rotation of the wheel (9) in the content filling station (6).

According to a thirteenth aspect of the present invention, in the methodof decontaminating an aseptic filling apparatus according to the first,fifth and sixth aspects of the present invention, the wheels (12, 13, 9,17 and the like) in the wheel train may be capable of being rotatedindependently of each other by a dedicated servo motor, and thededicated servo motor may be stopped to stop rotation of the wheel (9)in the content filling station (6).

According to a fourteenth aspect of the present invention, in the methodof decontaminating an aseptic filling apparatus according to the first,fifth and sixth aspects of the present invention, of the various kindsof stations, the stations other than the content filling station (6) maybe a container molding station, a container sterilizing station (5), acontainer sealing station (7) or a lid sterilizing station (53).

The invention according to a fifteenth aspect of the present inventionadopts an aseptic filling apparatus, comprising various kinds ofstations including a content filling station (6) arranged from anupstream side to a downstream side of a flow of a preform or containerfed by rotation of wheels (12, 13, 9, 17 and the like) in a wheel train,each of the various kinds of stations (5, 6, 7, 53) being covered by achamber (20, 21, 56), wherein a CIP (Step S1) of the content fillingstation (6) is performed after rotation of a wheel (9) in the contentfilling station (6) is stopped, a COP or SOP (Step S2) of the contentfilling station (6) is performed while the wheel (9) in the contentfilling station (6) is rotating immediately after the CIP (Step S1) iscompleted, an SIP (Step S3) of the content filling station (6) isperformed with rotation of the wheel (9) in the content filling station(6) being stopped immediately after the COP or SOP (Step S2) iscompleted, and one or both of the COP and SOP (Step S2) of the otherstations (5, 7, 53) is performed in a predetermined order while wheels(12, 13, 17 and the like) in the other stations (5, 7, 53) is rotatingin a period from the start of the CIP (Step S2) to the end of the SIP(Step S3).

According to a sixteenth aspect of the present invention, in the asepticfilling apparatus according to the fifteenth aspect of the presentinvention, the SOP (Step S2) of the content filling station (6) and theSOP (Steps S5, S6, S7) of the other stations (5, 7, 53) may be performedstepwise in a period from the start of the SOP (Step S2) to the end ofthe SIP (Step S3) of the content filling station (6).

According to a seventeenth aspect of the present invention, in theaseptic filling apparatus according to the fifteenth aspect of thepresent invention, the SOP (Step S2) of the content filling station (6)and the SOP (Steps S5, S6, S7) of the other stations (5, 7, 53) may beperformed in parallel between the stations (5, 6, 7, 53).

According to an eighteenth aspect of the present invention, in theaseptic filling apparatus according to the sixteenth or seventeenthaspects of the present invention, the SOP may be performed by blastingof a sterilizer and blasting of aseptic water.

The invention according to a nineteenth aspect of the present inventionadopts an aseptic filling apparatus, comprising various kinds ofstations including a content filling station (6) arranged from anupstream side to a downstream side of a flow of a preform or container(3) fed by rotation of wheels (12, 13, 9, 17 and the like) in a wheeltrain, each of the various kinds of stations (5, 6, 7, 53) being coveredby a chamber (20, 21, 56), a CIP (Step S1) of the content fillingstation (6) is performed after rotation of a wheel (9) in the contentfilling station (6) is stopped, the temperature of a cleaning liquid israised to a temperature required for an SIP subsequent to the CIP froman early stage or a middle of the CIP, the SIP (Step S2) of the contentfilling station (6) is performed to sterilize the content fillingstation (6) and the cleaning liquid is removed with rotation of thewheel (9) in the content filling station (6) kept stopped, and one orboth of a COP and an SOP (Step S3) of the content filling station (6) isperformed in a predetermined order while the wheel (9) in the contentfilling station (6) is rotating immediately after the SIP (Step S2) iscompleted.

The invention according to a twentieth aspect of the present inventionadopts an aseptic filling apparatus, comprising various kinds ofstations including a content filling station (6) arranged from anupstream side to a downstream side of a flow of a preform or container(3) fed by rotation of wheels (12, 13, 9, 17 and the like) in a wheeltrain, each of the various kinds of stations (5, 6, 7, 53) being coveredby a chamber (20, 21, 56), an SIP (Step S1), which serves also as a CIP,of the content filling station (6) is performed after rotation of awheel (9) in the content filling station (6) is stopped, and one or bothof a COP and an SOP (Step S2) of the content filling station (6) isperformed in a predetermined order while the wheel (9) in the contentfilling station (6) is rotating immediately after the SIP (Step S1) iscompleted.

According to a twenty-first aspect of the present invention, in theaseptic filling apparatus according to the nineteenth or twentiethaspects of the present invention, the SOP (Step S3) of the contentfilling station (6) and the SOP (Steps S5, S6, S7) of the other stations(5, 7, 53) may be performed stepwise immediately after the SIP (Step S2)of the content filling station (6) is completed.

According to a twenty-second aspect of the present invention, in theaseptic filling apparatus according to the nineteenth or twentiethaspects of the present invention, the SOP (Step S3) of the contentfilling station (6) and the SOP (Steps S5, S6, S7) of the other stations(5, 7, 53) may be performed in parallel with each other immediatelyafter the SIP (Step S2) of the content filling station (6) is completed.

According to a twenty-third aspect of the present invention, in theaseptic filling apparatus according to the nineteenth or twentiethaspects of the present invention, the SOP may be performed by blastingof hot water or a sterilizer and blasting of aseptic water.

According to a twenty-fourth aspect of the present invention, in theaseptic filling apparatus according to the fifteenth, nineteenth andtwentieth aspects of the present invention, the SOP (Step S4) of theother stations (5, 7, 53) may be performed while the CIP (Step S1) orSIP (Step S3) of the content filling station (6) is being performed, andthe SOP (Step S4) may be performed by blasting of gas or mist of asterilizer containing hydrogen peroxide.

According to a twenty-fifth aspect of the present invention, in theaseptic filling apparatus according to the fifteenth, nineteenth andtwentieth aspects of the present invention, aseptic air may beconstantly blasted to the content filling station (6) in the chamber(21).

According to a twenty-sixth aspect of the present invention, in theaseptic filling apparatus according to the fifteenth, nineteenth andtwentieth aspects of the present invention, a clutch that connects anddisconnects transmission of power between wheels may be provided betweenthe wheel (9) in the content filling station (6) and wheels (12, 13, 17and the like) in the container sterilizing station (5) and the containersealing station (7), and the clutch may be disconnected to stop rotationof the wheel (9) in the content filling station (6).

According to the twenty-seventh aspect of the present invention, in theaseptic filling apparatus according to the fifteenth, nineteenth andtwentieth aspects of the present invention, the wheels (12, 13, 9, 17and the like) in the wheel train may be capable of being rotatedindependently of each other by a dedicated servo motor, and thededicated servo motor may be stopped to stop rotation of the wheel (9)in the content filling station (6).

According to the twenty-eighth aspect of the present invention, in theaseptic filling apparatus according to the fifteenth, nineteenth andtwentieth aspects of the present invention, of the various kinds ofstations, the stations other than the content filling station (6) may bea container molding station, a container sterilizing station (5), acontainer sealing station (7) or a lid sterilizing station (53).

Advantageous Effects of Invention

According to the present invention, there is provided a method ofdecontaminating an aseptic filling apparatus, the aseptic fillingapparatus comprising various kinds of stations including a contentfilling station (6) arranged from an upstream side to a downstream sideof a flow of a preform or container (3) fed by rotation of wheels (12,13, 9, 17 and the like) in a wheel train, and each of the various kindsof stations being covered by a chamber (20, 21, 56), wherein a CIP (StepS1) of the content filling station (6) is performed after rotation of awheel (9) in the content filling station (6) is stopped, a COP or SOP(Step S2) of the content filling station (6) is performed while thewheel (9) in the content filling station (6) is rotating immediatelyafter the CIP (Step S1) is completed, an SIP (Step S3) of the contentfilling station (6) is performed with rotation of the wheel (9) in thecontent filling station (6) being stopped immediately after the COP orSOP (Step S2) is completed, and one or both of the COP and SOP (StepsS4, S5, S6, S7) of the other stations (5, 7) is performed in apredetermined order while wheels (12, 13, 17 and the like) in the otherstations (5, 7, 53) is rotating in a period from the start of the CIP(Step S1) to the end of the SIP (Step S3). Thus, when the CIP (Step S1)and the SIP (Step S3) of the content filling station (6) are performed,the COP or SOP (Steps S4, S5, S6, S7) of the other stations (5, 7) canbe performed with the wheels (12, 13, 17 and the like) rotating, andwhen the COP or SOP (Step S2) of the content filling station (6) isperformed while the wheel (9) in the content filling station isrotating, the COP or SOP (Steps S5, S6, S7) of the other stations (5, 7,53) can also be performed with the wheels (12, 13, 17 and the like)rotating.

Therefore, the COP or SOP of the various kinds of stations including thecontent filling station (6) can be efficiently performed, and thecleaning effect and the sterilization effect of the various kinds ofstations (5, 6, 7, 53) can be improved. Furthermore, the total time ofthe COP or SOP (Steps S2, S5, S6, S7) of the various kinds of stations(5, 6, 7, 53) can be reduced, so that the drink or other content fillingoperation can be started earlier, and the time out of production of theaseptic filling apparatus and the idle time due to changing of the kindof the drink can be reduced to improve the production efficiency.

In addition, according to the present invention, there is provided amethod of decontaminating an aseptic filling apparatus, the asepticfilling apparatus comprising various kinds of stations including acontent filling station (6) arranged from an upstream side to adownstream side of a flow of a preform or container (3) fed by rotationof wheels (12, 13, 9, 17 and the like) in a wheel train, and each of thevarious kinds of stations being covered by a chamber (20, 21, 56),wherein a CIP (Step S1) of the content filling station (6) is performedafter rotation of a wheel (9) in the content filling station (6) isstopped, the temperature of a cleaning liquid is raised to a temperaturerequired for an SIP subsequent to the CIP from an early stage or amiddle of the CIP, the SIP (Step S2) of the content filling station (6)is performed to sterilize the content filling station (6) and thecleaning liquid is removed with rotation of the wheel (9) in the contentfilling station (6) kept stopped, and one or both of a COP and an SOP(Step S3) of the content filling station (6) is performed in apredetermined order while the wheel (9) in the content filling station(6) is rotating immediately after the SIP (Step S2) is completed. Thus,the time required to shift from the CIP (Step S1) to the SIP (Step S2)of the content filling station (6) can be reduced.

Therefore, the cleaning effect and the sterilization effect of thecontent filling station (6) can be improved. Furthermore, the timerequired for the decontamination operation can be reduced, so that thedrink or other content filling operation can be started earlier, and thetime out of production of the aseptic filling apparatus and the idletime due to changing of the kind of the drink can be reduced to improvethe production efficiency.

In addition, according to the present invention, there is provided amethod of decontaminating an aseptic filling apparatus, the asepticfilling apparatus comprising various kinds of stations including acontent filling station (6) arranged from an upstream side to adownstream side of a flow of a preform or container (3) fed by rotationof wheels (12, 13, 9, 17 and the like) in a wheel train, and each of thevarious kinds of stations being covered by a chamber (20, 21, 56),wherein an SIP (Step S1), which serves also as a CIP, of the contentfilling station (6) is performed after rotation of a wheel (9) in thecontent filling station (6) is stopped, and one or both of a COP and anSOP (Step S2) of the content filling station (6) is performed in apredetermined order while the wheel (9) in the content filling station(6) is rotating immediately after the SIP (Step S1) is completed. Thus,the time required to clean and sterilize and thus decontaminate theinterior of the piping of the content filling station (6) can bereduced.

Therefore, the time required for the decontamination operation of thecontent filling station (6) can be reduced, so that the drink or othercontent filling operation can be started earlier, and the time out ofproduction of the aseptic filling apparatus and the idle time due tochanging of the kind of the drink can be reduced to improve theproduction efficiency.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic plan view of an aseptic filling apparatusaccording to the present invention.

FIG. 2 is a schematic diagram showing a sterilizer vaporizer in theaseptic filling apparatus.

FIG. 3 is a schematic diagram showing a content filling station in theaseptic filling apparatus, the left half showing a state of the stationduring drink filling and the right half showing a state of the stationduring cleaning or sterilization.

FIG. 4 is a flowchart showing a decontaminating method for the asepticfilling apparatus.

FIG. 5 is a flowchart showing another decontaminating method.

FIG. 6 is a flowchart showing a conventional decontaminating method foran aseptic filling apparatus.

FIG. 7 is a flowchart showing a decontaminating method for the asepticfilling apparatus.

FIG. 8 is a diagram for illustrating a process of shifting from a CIP toa SIP of the interior of a drink supply piping in FIG. 7 .

FIG. 9 is a flowchart showing another decontaminating method.

FIG. 10 is a flowchart showing further another decontaminating method.

FIG. 11 is a flowchart showing a conventional decontaminating method foran aseptic filling apparatus.

FIG. 12 is a diagram for illustrating a process of shifting from the CIPto the SIP of the interior of the drink supply piping in FIG. 11 .

FIG. 13 is a graph showing a relationship between the temperature of afilling nozzle and a hydrogen peroxide gas concentration insterilization of an outer surface of the filling nozzle.

FIG. 14 is a flowchart showing a decontaminating method for the asepticfilling apparatus.

FIG. 15 is a diagram for illustrating a process of shifting from the CIPto the SIP of the interior of the drink supply piping in FIG. 14 .

FIG. 16 is a flowchart showing another decontaminating method.

FIG. 17 is a flowchart showing further another decontaminating method.

DETAILED DESCRIPTION OF THE INVENTION

In the following, embodiments of the present invention will be describedwith reference to the drawings.

First Embodiment

As shown in FIG. 1 , an aseptic filling apparatus includes a preformsupplying station 2 that successively supplies preforms 1 atpredetermined intervals, a container molding station 4 that molds thepreform 1 into a bottle 3 (see FIG. 3 ), which is a container, acontainer sterilizing station 5 that sterilizes the molded bottles 3, acontent filling station 6 that fills the sterilized bottles 3 with acontent such as a drink, and a container sealing station 7 that sealsthe bottles 3 filled with the content.

The preform 1 is a bottomed tubular body similar to a test tube and isformed from polyethylene terephthalate (PET), for example, by injectionmolding or the like. The preform 1 is eventually to be shaped by blowmolding into the bottle 3, which is a container, in the containermolding station 4. However, a mouth portion 3 a (see FIG. 3 ), a malethread and the like similar to those of the finished bottle 3 are formedon the preform 1 in the early stage of the molding of the preform 1.

Between the preform supplying station 2 and the container sealingstation 7, there are provided a preform conveying path that conveys thepreform 1 in one direction, a molding die conveying path that conveys inone direction a molding die 8 that molds the preform 1 into the bottle3, and a bottle conveying path that conveys the bottle 3 molded in themolding die 8 in one direction.

The conveying paths described above are formed by respective conveyingmeans. The preform conveying path is formed by a combination of ashooter and a wheel, for example, and the conveying path from themolding die conveying path to the bottle conveying path is formed by awheel train formed by a combination of various wheels. Furthermore, agripper or the like (not shown) for holding the preform 1 or the bottle3 at the mouth portion 3 a thereof during conveyance and passing thepreform 1 or the bottle 3 between wheels is provided around apredetermined wheel.

The various conveying paths described above are integrally driven by amotive power from a predetermined power source, and the wheels or thelike in the conveying paths are driven in association with each other.

According to the first embodiment, a clutch (not shown) that connectsand disconnects transmission of power is provided in a powertransmission system for a wheel 9 of the content filling station 6, forexample. By disengaging the clutch, rotation of the wheel 9 of thecontent filling station 6 can be stopped while the other wheels or thelike are kept moving.

Instead of providing the clutch, each wheel in the wheel train can berotated independently of each other by a dedicated servo motor. In thatcase, rotation of the wheel 9 of the content filling station 6 can bestopped by stopping the relevant dedicated servo motor, while the otherdedicated servo motors and the respective other wheels can be keptrotating.

The preform supplying station 2 is disposed along the flow of thepreforms 1 traveling on the preform conveying path, the containermolding station 4 is disposed along the outer periphery of apredetermined wheel 10 of the molding die conveying path, and thecontainer sterilizing station 5, the content filling station 6 and thecontainer sealing station 7 are disposed along the flow of the bottles 3fed by rotating wheels 11, 12, 13, 14, 15, 9, 16, 17 and 18 of the wheeltrain, in this order from upstream to downstream.

Portions of the aseptic filling apparatus from the preform supplyingstation 2 to the container molding station 4 including the conveyingpaths for the preforms 1 and the like are covered by a first chamber 19serving as a protective cover, the container sterilizing station 5including the bottle conveying path is covered by a second chamber 20,and the content filling station 6 and the container sealing station 7including the bottle conveying path are covered by a third chamber 21.

The first to third chambers 19, 20 and 21 are arranged adjacent to eachother and separated from each other by partition walls. An exhaust duct(not shown) is coupled to the second chamber 20, so that air in thesecond chamber 20 is constantly discharged to the outside of the secondchamber 20 during operation of the aseptic filling apparatus.Furthermore, in the third chamber 21, the content filling station 6 andthe container sealing station 7 are separated by a partition wall.During operation of the aseptic filling apparatus, aseptic air isconstantly supplied from an aseptic air supply source (not shown) to thepart of the third chamber 21 containing the content filling station 6,thereby keeping the interior of the third chamber 21 at a positivepressure. The aseptic air supplied to the part containing the contentfilling station 6 flows into the part containing the container sealingstation 7 through a clearance in the partition wall through which thebottles pass.

The preform conveying path and the preform supplying station 2 of theaseptic filling apparatus will be first described. The preform conveyingmeans includes a shooter 22 that successively supplies preforms 1 atpredetermined intervals, a wheel 23 that receives the preforms 1 from aterminal end of the shooter 22 and conveys the preforms 1, and anendless chain 24 that extends in a horizontal direction, receives thepreforms 1 from the wheel 23 and transfers the preforms 1.

The endless chain 24 is stretched between a pair of pulleys 24 a and 24b that are disposed to be opposed to each other in a horizontal plane,and the shooter 22 is connected to one 24 a of the pulleys.

A large number of holding members (not shown) for preforms 1 areattached to the endless chain 24 at regular intervals. Each holdingmember can rotate on its axis while moving with the endless chain 24.The holding member is formed as a spindle and has a plurality ofball-shaped elastic bodies embedded in an outer surface of a lowerportion thereof. Once the holding member is inserted into the mouthportion 3 a of the preform 1, the elastic bodies are elasticallydeformed to hold the preform 1 on the holding member.

The holding member is inserted into the mouth portion 3 a of the preform1 passed from the wheel 23 to the endless chain 24, and thus, thepreform 1 is held in an upright position by the holding member.

The endless chain 24 is surrounded by a furnace wall of a heatingfurnace, and a heater 25 that emits infrared rays is provided all overan inner surface of the furnace wall.

The preform 1 is received by the holding member attached to the endlesschain 24 via the shooter 22, travels with endless chain 24 moving and isheated by the heater 25 to a temperature that allows blow molding.Preferably, the preform 1 is uniformly heated by rotating on its axis asthe holding member rotates until the temperature of the preform 1excluding the mouth portion 3 a rises to 90° C. to 130° C., which is atemperature range suitable for blow molding. The temperature of themouth portion 3 a is kept to be equal to or lower than 70° C., at whichno deformation or the like occurs, so that sealing between the mouthportion 3 a and a cap 51 (see FIG. 1 ) to be fitted on the mouth portion3 a is not compromised.

At a position where the pulley 24 a at one end of the endless chain 24is connected to the return run of the endless chain 24, a wheel 26 thatreceives the preform 1 heated by the heater 25 and passes the preform 1to the molding die 8 on the second conveying path is provided adjacentto the pulley 24 a.

Next, the molding die conveying path and the container molding station 4will be described. The molding die conveying path includes a wheel trainincluding a wheel 26 adjacent to the pulley 24 a in the preformconveying path and wheels 10 and 11.

A plurality of molding dies 8, which are a plurality of sets of splitdies, that receive the preform 1 heated by the heater 25 and blow moldthe preform 1 into the bottle 3 are disposed around the wheel 10 atpredetermined intervals. The molding dies 8 can rotate at a constantvelocity around the wheel 10 as the wheel 10 rotates.

Once the finished bottle 3 is exposed in the molding die 8 opened, thebottle 3 is removed out of the molding die 8 by a gripper disposedaround the wheel 11 adjacent to the wheel 10 and passed a gripper aroundthe wheel 12 downstream thereof.

A camera 55 is disposed at a position along the outer periphery of thewheel 11. The camera 55 images a top surface of the mouth portion 3 a ofthe bottle 3, and whether the smoothness of the top surface isappropriate or not is determined based on the image.

Next, the bottle conveying path and the container sterilizing station 5will be described. The bottle conveying path includes a wheel trainincluding the wheels 11, 12, 13, 14, 15, 9, 16, 17 and 18.

The container sterilizing station 5 includes a sterilizer sprayingnozzle 27 and an air rinsing nozzle 28 arranged around the wheels 12 and13, respectively, in the wheel train.

The sterilizer spraying nozzle 27 is disposed with a nozzle injectionhole thereof being opposed to the opening of the mouth portion 3 a ofthe bottle 3 traveling around the wheel 12, and a sterilizer vaporizer29 illustrated in FIG. 2 is connected to the sterilizer spraying nozzle27 at the upstream side thereof.

The sterilizer effectively contains 1% by mass or more of hydrogenperoxide. Alternatively, the sterilizer may contain one or more ofethanol, peracetic acid, ozone, chlorine dioxide and a chlorine-basedsterilizer or a mixture thereof.

The vaporizer 29 includes a hydrogen peroxide supplying portion 30 thatis a twin-fluid spray that sprays a hydrogen peroxide solution servingas a sterilizer and a vaporizing portion 31 that vaporizes a spray ofhydrogen peroxide supplied from the hydrogen peroxide supplying portion30 by heating the spray of hydrogen peroxide to a temperature equal toor higher than the boiling point thereof and equal to or lower than thenon-degradable temperature thereof. The hydrogen peroxide supplyingportion 30 is configured to receive the hydrogen peroxide solution andcompressed air from a hydrogen peroxide supply path 30 a and acompressed air supply path 30 b, respectively, and sprays the hydrogenperoxide solution into the vaporizing portion 31. The vaporizing portion31 is a pipe that incorporates a heater 31 a disposed between inner andouter walls thereof, and heats and vaporizes the spray of hydrogenperoxide blasted into the pipe. The vaporized hydrogen peroxide isejected in the form of a mist or gas or a mixture thereof from thesterilizer spraying nozzle 27 to the outside of the vaporizer 29. Someof the hydrogen peroxide flows into the bottle 3, and some flows alongthe outer surface of the bottle 3, so that a uniform coating of hydrogenperoxide is formed on the inner and outer surfaces of the bottle 3.

The air rinsing nozzle 28 is arranged with a nozzle injection holethereof being opposed to the opening of the mouth portion 3 a of thebottle 3 traveling around the wheel 13.

For example, one or more air rinsing nozzles 28 are arranged around thewheel 13. Alternatively, the air rinsing nozzle 28 may be arrangedaround the wheel 14 or 15 rather than the wheel 13. Air rinsing nozzles28 may be arranged around the wheels 13, 14 and 15.

While the bottle 3 to which the sterilizer has been blasted is travelingaround the wheel 13, aseptic air is blasted to the mouth portion 3 a ofthe bottle 3 from the air rinsing nozzle 28. In this way, the hydrogenperoxide remaining on the inner and outer surfaces of the bottle 3 isdecomposed and removed. The sterilized bottle 3 reaches the subsequentcontent filling station 6 via the wheels 14 and 15.

The aseptic air may be heated air. In that case, the hydrogen peroxideremaining on the inner and outer surfaces of the bottle 3 is activated,so that the effect of sterilization of the bottle 3 is improved.

The container sterilizing station 5 can be omitted if a preformsterilizing station is provided at a position in the travel route of thepreforms 1 to sterilize the preforms 1. Although not shown, in thepreform sterilizing station, a nozzle for blasting a sterilizer such ashydrogen peroxide to the preforms is provided at a predeterminedposition around the wheel 23, the endless chain 24 or the wheel 26.

The content filling station 6 is configured as a filler integrated withthe wheel 9 in the bottle conveying path.

The content filling station 6 has a large number of filling nozzles 32around the wheel 9. Each filling nozzle 32 rotates with the wheel 9, andthe bottle 3 travels below the filling nozzle 32 in synchronization withthe filling nozzle 32. Thus, each filling nozzle 32 fills the relevantbottle 3 with a drink.

As shown in FIG. 3 , drink supply piping 34 that extends from a drinkpreparation tank (not shown) is connected to the content filling station6 via a surge tank 3. The drink prepared in the preparation tank issterilized in a heater (not shown) in the drink supply piping 34 andthen supplied to the content filling station 6.

The filler serving as the content filling station 6 is a unit that fillsa large number of bottles 3 with the drink at high rate and includes thewheel 9, which forms a part of the conveying path for the bottles 3, asshown in FIG. 3 . The wheel 9 is attached to a part of a pivot 35 a of aspindle 35 that stands vertically from a floor surface of the asepticfilling apparatus. Grippers 36 that grasp neck portions of the bottles 3are arranged at regular intervals around the wheel 9. The grippers 36can rotate in one direction integrally with the wheel 9. In addition,the large number of filling nozzles 32 are arranged at the sameintervals as the grippers 36 around the wheel 9.

An upper part of the spindle 35 is fixed to a casing of the contentfilling station 6, and a rotary joint 35 b is provided between the fixedupper part and an upper end of the pivot 35 a. An upper manifold 37 isarranged on the pivot 35 a at a position below the rotary joint 35 b. Apart of the spindle 35 from the top to the upper manifold 37 is hollow,and the drink supply piping 34 is coupled to the top of the spindle 35.The drink supply piping 34 extends from the upper manifold 37 to thefilling nozzles 32.

In operation of the content filling station 6, the wheel 9 rotates athigh speed, and the bottles 3 grasped by the grippers 36 are conveyed athigh speed on the bottle conveying path in synchronization with therotation of the wheel 9. Since the large number of bottles 3 travels ina line directly below a nozzle mouth 32 a of the filling nozzle 32, apredetermined amount of the drink is supplied successively to eachbottle 3.

The container sealing station 7 is configured as a capper integratedwith the wheel 17 in the bottle conveying path and is covered by thechamber 21, which also covers the content filling station 6.

While the bottle 3 that has been filled with the drink in the contentfilling station 6 while traveling on the bottle conveying path istraveling around the wheel 17 of the capper, a cap 51 is screwed ontothe mouth portion 3 a of the bottle 3. In this way, an aseptic bottleddrink is finished.

As shown in FIG. 1 , the capper is provided with a cap sterilizingstation 53, which is a station for sterilizing caps.

The cap 51 that closes the mouth portion 3 a of the bottle 3 ispreviously sterilized in the cap sterilizing station 53 before the cap51 is supplied to the container sealing station 7. The cap sterilizingstation 53 is also covered by a chamber to maintain the asepticcondition of the cap sterilizing station 53.

A large number of caps previously molded are supplied to the capsterilizing station 53. The caps are sterilized by blasting a spray of asterilizer such as hydrogen peroxide to the caps traveling in the capsterilizing station 53 and then blasting aseptic hot air to the caps.The sterilized caps are supplied from the cap sterilizing station 53 tothe capper by a shooter or the like.

During manufacture of the bottled drink, aseptic air, desirably aseptichot air, is constantly blasted from the aseptic air supply source to thecontent filling station 6 in the chamber 21. This ensures that theatmosphere in the chamber 21 is kept at a positive pressure, and theoutside air containing bacteria, dust or the like is prevented fromentering the chamber 21. Furthermore, the aseptic air also flows to thecontainer sealing station 7 in the same chamber 21 and the containersterilizing station 5 in the chamber 20, so that the outside air is alsoprevented from entering the container sealing station 7 and the like. Inaddition, aseptic air is also constantly supplied into the chamber 56for the cap sterilizing station 53 from another aseptic air supplysource (not shown).

The aseptic filling apparatus is provided with decontaminatingapparatuses for the container molding station 4, the containersterilizing station 5, the content filling station 6, the containersealing station 7 and the cap sterilizing station 53 contained in therespective chambers 20, 21 and 56, and the decontaminating apparatusperforms a decontamination process including CIP, SIP, COP and SOP atregular intervals or when to change the kind of the drink by stoppingthe drink filling operation.

The decontaminating apparatus does not need to be provided for all thestations and can be omitted for a station that does not need adecontaminating apparatus.

First, a decontaminating apparatus for the content filling station 6will be described.

As described above, the drink is supplied from the preparation apparatusto the filling nozzle 32 in the content filling station 6 through thedrink supply piping 34. The interior of the drink supply piping 34 issubjected to the CIP, then to the SOP or COP, and eventually to the SIPat regular intervals or when to change the kind of the drink.

In FIG. 3 , reference numeral 38 denotes a reservoir tank, which is asupply source of a working fluid serving as a cleaning liquid orsterilizing liquid used for the CIP, and reference numeral 39 denotes aliquid feeding pump. The number of reservoir tanks 38 provided dependson the kind of the working fluid, although only one reservoir tank isshown for convenience of drawing. Illustration of a supply source of thesterilizing fluid such as vapor is omitted.

In FIG. 3 , reference numeral 40 denotes a feed pipe that extends fromthe reservoir tank 38 to the surge tank 33, and reference numeral 41denotes a return pipe that extends from each filling nozzle 32 to thereservoir tank 38. In cooperation with the drink supply piping 34, thefeed pipe 40 and the return pipe 41 form a circulation path for thecleaning liquid or the like.

The return pipe 41 is provided with a cup 42 at a leading end thereof,and the cup 42 can be connected to and separated from the nozzle mouth32 a of the relevant filling nozzle 32. When to perform the CIP or SIP,an actuator (not shown) places each cup 42 over the nozzle mouth 32 a atthe tip end of the relevant filling nozzle 32 in the content fillingstation 6, thereby connecting the leading end of the return pipe 41 tothe nozzle mouth 32 a of the filling nozzle 32. Each cup 42 is coupledto a lower manifold 43 by a flexible pipe that forms a part of thereturn pipe 41. The lower manifold 43 is attached to the pivot 35 a andcan rotate integrally with the wheel 9, the filling nozzle 32 and thelike.

The return pipe 41 is provided with a disconnectable coupling 44 at apart where the return pipe 41 extends from the lower manifold 43 to thereservoir tank 38. When the CIP or SIP is performed, the coupling 44 isconnected. In this state, the wheel 9, the filling nozzles 32 and thelike are inhibited from rotating. When the CIP or SIP is completed, andthe coupling 44 is disconnected, the wheel 9, the filling nozzles 32 andthe like are allowed to rotate.

According to the first embodiment, as shown in FIG. 4 , a controllingportion (not shown) is programmed to successively perform the CIP, theSOP or COP, and the SIP of the content filling station 6.

First, before starting the CIP (Step S1) of the content filling station6, the clutch in the power transmission system of the aseptic fillingapparatus is disconnected to stop rotation of only the wheel 9 of thecontent filling station 6, thereby stopping rotation of the fillingnozzles 32. In addition, the surge tank 33 is emptied.

As shown in the right half of FIG. 3 , the nozzle mouth 32 a of thefilling nozzle 32 is then closed by the cup 42. In addition, thecoupling 44 is connected. In this way, a circulation path for flowing apredetermined working fluid for the CIP such as a cleaning liquid orsterilizing liquid is formed.

The CIP (Step S1) is then started, and a predetermined working fluidsuch as an alkali cleaner or water is fed from the reservoir tank 38 bya pump 39 in a predetermined order. The cleaning liquid or the likeflows through the feed pipe 40 from the reservoir tank 38 to the surgetank 33, passes through the drink supply piping 34, flows into the uppermanifold 37 and then to each filling nozzle 32, and eventually returnsto the reservoir tank 38 through the return pipe 41. Thus, the cleaningliquid or the like flows in the circulation path for a predeterminedtime in a predetermined order to clean the interior of the drink supplypiping 34 including the interior of the filling nozzles 32.

Immediately after the CIP (Step S1) is completed, the SOP or COP (StepS2) (described later) is performed. Immediately after the SOP or COP iscompleted, the SIP (Step S3) is performed. The SIP is performed bypassing the sterilizing working fluid such as hot water or vapor throughthe drink supply piping 34. The hot water or the like passing throughthe drink supply piping 34 sterilizes the interior of the drink supplypiping 34. Illustration of a supply source of hot water, vapor or thelike is omitted.

In FIG. 3 , reference numeral 45 denotes an injection nozzle for the SOPor COP (Step S2) arranged to be opposed to each of different parts ofthe content filling station 6 in the chamber 21. The injection nozzles45 are fixed to the interior of the chamber 21 at predeterminedlocations.

Reference numeral 46 denotes a reservoir tank, which is a supply sourceof a predetermined working fluid, such as a liquid chemical agent suchas an alkali cleaner, a peracetic acid cleaner or a hydrogen peroxidesolution, or aseptic water. The reservoir tank 46 is provided for eachof different liquid chemical agents such as a hydrogen peroxide solutionor aseptic water, although only one reservoir tank 46 is shown forconvenience of drawing. Reference numerals 47 and 48 denote supply pipesextending from each reservoir tank 46 to the injection nozzle 32described above. Each of the supply pipes 47 and 48 is provided with apump 49.

Alternatively, the pumps 39, 49 and the like may be omitted, and thereservoir tanks 38 and 46 may be located at high elevations so that thecleaner, liquid chemical agent or the like can be supplied into thechamber 21 or the like under hydrostatic pressure.

When the CIP (Step S1) of the interior of the drink supply piping 34 inthe content filling station 6 is completed, and the coupling 44 isdisconnected, the clutch described above is connected, so that the wheel9 is allowed to rotate in association with the other wheels 13, 17 andthe like. Alternatively, the wheel 9 is allowed to rotate by beingdriven by the dedicated servo motor for the wheel 9.

When the wheel 9 starts rotating, the SOP or COP (Step S2) in thechamber 21 is started.

The SOP or COP (Step S2) of the content filling station 6 in the chamber21 is performed by blasting the sterilizer such as a peracetic acidsolution from the injection nozzles 45 to the exterior of the contentfilling station 6 and then blasting aseptic water from the sameinjection nozzles 45. The sterilizer blasted to the content fillingstation 6 sterilizes the outer surface of the content filling station 6,and the aseptic water subsequently blasted washes the remainder of thedrink in the previous filling operation and the sterilizer such asperacetic acid from the surface of the content filling station 6.

During the SOP or COP (Step S2), the filling nozzles 32 or the likerotate with the wheel 9. Since the working fluid is blasted to therotating content filling station 6, foreign matters or the like areefficiently washed from the outer surface of the filling nozzles 32,which have a particularly complicated shape and structure, and thesurface of the filling nozzles 32 is efficiently sterilized.

In the period from the start of the CIP (Step S1) to the end of the SIP(Step S3), aseptic air, desirably aseptic hot air, is constantly blastedfrom the aseptic air supply source described above to the contentfilling station 6 in the chamber 21. This ensures that the atmosphere inthe chamber 21 is kept at a positive pressure, and the outside aircontaining bacteria, dust or the like is prevented from entering thechamber 21. Furthermore, the aseptic air also flows to the containersealing station 7 in the same chamber 21 and the container sterilizingstation 5 in the chamber 20, so that the outside air is also preventedfrom entering the container sealing station 7 and the like.

The decontaminating apparatuses for the container molding station 4, thecontainer sealing station 7, the container sterilizing station 5 and thecap sterilizing station 53 will be now described. In order to performone or both of the SOP and COP (Steps S4, S5, S6, S7) of the stations 4,7, 5 and 53, as shown in FIG. 1 , injections nozzles 57 having the samestructure as the injection nozzles 45 are arranged at locations in thechamber 19 so as to be opposed to the container molding station 4,injection nozzles 52 having the same structures as the injection nozzles45 are arranged at locations in the chamber 21 so as to be opposed tothe container sealing station 7, injection nozzles 50 having the samestructures as the injection nozzles 45 are arranged at locations in thechamber 20 so as to be opposed to the container sterilizing station 5,and injection nozzles 54 having the same structure as the injectionnozzles 45 are arranged at locations in the chamber 56 so as to beopposed to the cap sterilizing station 53.

Supply pipes (not shown) extend from the reservoir tank 46 to theinjection nozzles 57, 52, 50 and 54, and the supply pipes are alsoprovided with a pump (not shown) that feeds a liquid chemical agent orthe like to these pipes under pressure.

As shown in FIG. 4 , the controlling portion (not shown) is programmedto perform the SOP or COP (Steps S4, S5, S6, S7) of the containermolding station 4, the container sealing station 7, the containersterilizing station 5 and the cap sterilizing station 53 in the periodfrom the start of the CIP (Step S1) to the end of the SIP (Step S3) ofthe content filling station 6. In addition, the controlling portion isprogrammed to perform two types of SOP (Steps S4, S5, S6, S7) on eachstation.

As shown in FIG. 4 , the SOP performed first (Step S4) is performed insynchronization with the CIP (Step S1) of the content filling station 6and performed simultaneously for all of the container molding station 4,the container sealing station 7, the container sterilizing station 5 andthe cap sterilizing station 53.

The SOP or COP (Step S4) is different from the SOP or COP (Step S2) ofthe content filling station 6 and is performed by spraying a hydrogenperoxide solution from the injection nozzles 57, 50, 52 and 54 to theouter surface of the container molding station 4, the containersterilizing station 5, the container sealing station 7 and the capsterilizing station 53. In the SOP or COP (Step S4), the hydrogenperoxide solution may be sprayed from the injection nozzles 45 to thecontent filling station 6 at the same time and dried and vaporized byaseptic hot air.

In the SOP or COP (Step S4), the hydrogen peroxide solution serving as aworking fluid is blasted to each of the stations 4, 5, 7 and 53 whilethe wheels 10, 12, 13 and the like other than the wheel 9 are rotating,so that the sterilization effect of the stations 4, 5, 7 and 53 isimproved.

That is, in the CIP (Step S1), although the clutch is disconnected tostop the wheel 9 of the content filling station 6 as described above,the other wheels 17 and the like can rotate. In the alternative case,even if the dedicated servo motor for the wheel 9 of the content fillingstation 6 is stopped, the other wheels 17 and the like can rotate bybeing driven by the respective dedicated servo motors. Thus, even if thewheel 9 of the content filling station 6 is stopped when the CIP (StepS1) of the content filling station 6 is performed, the other wheels 17and the like of the other stations such as the container sterilizingstation 5 can rotate, so that the SOP or COP (Step S4) of the outersurface of the stations other than the content filling station 6, thatis, the container molding station 4, the container sterilizing station5, the container sealing station 7 and the cap sterilizing station 53,can be effectively performed.

The sterilizer used for the SOP effectively contains 1% or more ofhydrogen peroxide. Alternatively, the sterilizer may contain one or moreof ethanol, peracetic acid, acetic acid, octanoic acid, peroxyoctanoicacid, ozone, chlorine dioxide, chlorinated alkali and sodiumhypochlorite or a mixture thereof. The sterilizer may be gas or mist,rather than liquid.

When the SOP or COP (Step S4) is performed, if aseptic hot air has beenblasted into the chambers 19, 20, 21 and 56 before spraying the hydrogenperoxide solution, the temperature of the atmosphere in the chambers 19,20, 21 and 56 increases, so that the hydrogen peroxide is activated, andthe effect of sterilization by the SOP or COP (Step S4) is improved.After spraying of the hydrogen peroxide solution, the aseptic hot airpromotes drying and removal of any excessive hydrogen peroxide solution.

The SOP or COP (Steps S5, S6, S7) that follows the SOP or COP (Step S4)described above is different from the SOP or COP (Step S4) and is thesame as the SOP or COP (Step S2) of the content filling station 6. TheSOP or COP (Steps S5, S6, S7) is performed stepwise for the containersealing station 7, the container sterilizing station 5 and the capsterilizing station 53 in the period from the SOP or COP (Step S2) ofthe content filling station 6 to the end of the SIP (Step S3).

In the different SOP or COP (Steps S5, S6, S7), a peracetic acidsolution is first blasted from the injection nozzles 52, 50 and 54 tothe container sealing station 7, the container sterilizing station 5 andthe cap sterilizing station 53 to sterilize the outer surface of thestations 7, 5 and 53, and aseptic water is then blasted to the stationsto wash the remainder of the drink in the previous filling, theexcessive peracetic acid solution or the like from the surface of thestations 7, 5 and 53.

When the SIP (Step S3) of the content filling station 6 is performed,although the wheel 9 of the content filling station 6 is stopped, theother wheels 12, 13 and the like of the container sealing station 7, thecontainer sterilizing station 5 and the cap sterilizing station 53 canrotate. Thus, when the SOP or COP (Steps S5, S6, S7) of the containersealing station 7, the container sterilizing station 5 and the capsterilizing station 53 in the chambers 20, 21 and 56 is performed in theperiod from the SOP or COP (Step S2) to the SIP (Step S3) of the contentfilling station 6, the cleaning effect of the stations 7, 5 and 53 byblasting of peracetic acid or aseptic water as a working fluid isimproved.

When the SOP or COP (Steps S5, S6, S7) is performed, the aseptic hot airis blasted into the chambers 21, 20 and 56.

According to the first embodiment, as shown in FIG. 4 , the SOP or COP(Steps S2, S5, S6, S7) using peracetic acid and aseptic water of thecontent filling station 6, the container sealing station 7, thecontainer sterilizing station 5 and the cap sterilizing station 53 isperformed stepwise in the period from the start of the SOP or COP (StepS2) to the end of the SIP (Step S3) of the content filling station 6,because it is difficult to supply the peracetic acid and aseptic waterto all the stations at the same time.

In this process, the cleaning with the aseptic water in each precedingSOP or COP and the cleaning with the peracetic acid in the subsequentSOP or COP are preferably performed in a temporally overlapped manner.This is intended to prevent the peracetic acid supplied in each SOP orCOP from adhering to a part where the peracetic acid in the precedingSOP or COP is being washed and removed.

When the SOP or COP (Steps S5, S6, S7) is performed, if the sterilizeror cleaner such as peracetic acid comes into contact with the fillingvalves 32, heat of the filling valves 32 is lost, and thus the fillingvalves 32 can be poorly sterilized. To avoid this, a partition wall thatprevents the sterilizer or cleaner from flowing to the content fillingstation 6 is preferably provided between the content filling station 6and the other stations. Alternatively, gas or mist of the sterilizer,rather than the sterilizing liquid, is preferably used as a sterilizerfor the SOP or COP in the other chambers.

Next, operations of the aseptic filling apparatus described above and amethod of decontaminating the aseptic filling apparatus will bedescribed.

(1) First, a decontamination operation of the aseptic filling apparatuswill be described with reference to the flowchart of FIG. 4 .

When manufacture of the bottled drink is finished, and manufacture ofanother kind of bottled drink is started by changing the kind of drink,the CIP (Step S1), the SIP (Step S3) and the SOP or COP (Steps S2, S5,S6, S7) are performed on the aseptic filling apparatus.

In the period from the start of the CIP (Step S1) to the end of the SIP(Step S3), aseptic hot air is preferably constantly blasted to thecontent filling station 6 in the chamber 21. This ensures that theatmosphere in the chamber 21 is kept at a positive pressure, and theoutside air containing bacteria, dust or the like is prevented fromentering the chamber 21. The aseptic air also flows to the containersealing station 7 in the same chamber 21 and the container sterilizingstation 5 in the chamber 20, so that contamination of the containersealing station 7 and the like is also prevented. Aseptic air is alsosupplied into the chamber 56 for the cap sterilizing station 53.

(2) Before starting the CIP (Step S1) of the content filling station 6,the clutch in the power transmission system of the aseptic fillingapparatus is disconnected to stop rotation of only the wheel 9 of thecontent filling station 6, thereby stopping rotation of the fillingnozzles 32. In addition, the surge tank 33 is emptied.

(3) As shown in the right half of FIG. 3 , the nozzle mouth 32 a of thefilling nozzle 32 is then closed by the cup 42. In addition, thecoupling 44 is connected. In this way, a circulation path for flowing apredetermined working fluid for the CIP (Step S1) such as a cleaningliquid or sterilizing liquid is formed.

(4) The CIP (Step S1) is started, and a predetermined working fluid suchas an alkali cleaner or water is fed from the reservoir tank 38 by thepump 39 in a predetermined order. The cleaning liquid or the like flowsthrough the feed pipe 40 from the reservoir tank 38 to the surge tank33, passes through the drink supply piping 34, flows into the uppermanifold 37 and then to each filling nozzle 32, and eventually returnsto the reservoir tank 38 through the return pipe 41. Thus, the cleaningliquid or the like flows in the circulation path for a predeterminedtime in a predetermined order to clean the interior of the drink supplypiping 34 including the interior of the filling nozzles 32.

(5) After the CIP (Step S1) is completed, the clutch in the powertransmission system of the aseptic filling apparatus is connected, sothat the wheel 9 of the content filling station 6 starts rotating alongwith the other wheels, and thus the filling nozzles 32 also startrotating.

In response to this, the SOP or COP (Step S2) of the content fillingstation 6 is started, and a predetermined working fluid such a liquidchemical agent or aseptic water is injected from the injection nozzles45 to the exterior of the content filling station 6 in a predeterminedorder. Since the working fluid is blasted to the rotating fillingnozzles 32 and the like, the outer surface of the filling nozzles 32 andthe like is efficiently cleaned and sterilized.

The SOP or COP of Step S2 may be a process of deactivating bacteria byusing warm water or the like of a temperature equal to or higher than60° C. and lower than 100° C. instead of the sterilizer.

In the SOP or COP (Step S2) according to the first embodiment, theperacetic acid solution as a sterilizer is first blasted from theinjection nozzles 45 to the content filling station 6 to sterilize theouter surface of the content filling station 6, and aseptic water isthen blasted to wash any excessive peracetic acid as a sterilizer ordirt from the surface of the content filling station 6.

(6) When the SOP or COP (Step S2) of the content filling station 6 iscompleted, the clutch in the power transmission system of the asepticfilling apparatus is disconnected to stop rotation of only the wheel 9in the content filling station 6, thereby stopping rotation of thefilling nozzles 32.

(7) As shown in the right half of FIG. 3 , the nozzle mouth 32 a of thefilling nozzle 32 is then closed by the cup 42. In addition, thecoupling 44 is connected. In this way, a circulation path for flowing apredetermined working fluid for the SIP (Step S3) such as a cleaningliquid or sterilizing liquid is formed.

(8) The SIP (Step S3) is started, and a predetermined working fluid suchas hot water or heated vapor is fed from a supply source of hot water orthe like (not shown) to the circulation path described above for apredetermined time. In this way, the interior of the drink supply piping34 including the filling nozzles 32 is sterilized.

(9) When the CIP (Step S1) of the drink supply piping 34 of the contentfilling station 6 is performed, the SOP or COP (Step S5) is performed inparallel therewith on (i) the outer surface of various kinds ofequipment in the container molding station 4 in the chamber 19, (ii) theouter surface of various kinds of equipment in the container sterilizingstation 5 in the chamber 20, (iii) the outer surface of various kinds ofequipment in the container sealing station 7 in the chamber 21, and (iv)the outer surface of various kinds of equipment in the chamber 56 forthe cap sterilizing station 53.

In this process, the wheel 9 of the content filling station 6 isstopped, while the equipment, such as the wheels 10, 12, 13, 17 and 18,in the container molding station 4, the container sterilizing station 5,the container sealing station 7 and the cap sterilizing station 53 arebeing driven.

The SOP or COP (Step S4) is different from the SOP or COP (Step S2) ofthe content filling station 6 in that a hydrogen peroxide solution isblasted from the injection nozzles 57, 50, 52 and 54 to the outersurface of the container molding station 4, the container sterilizingstation 5, the container sealing station 7 and the cap sterilizingstation 53.

In this process, since the container molding station 4, the containersterilizing station 5, the container sealing station 7 and the capsterilizing station 53 are being driven, the hydrogen peroxide solutionas a working fluid spreads into every corner of the various kinds ofequipment thereof to improve the cleaning effect and the sterilizationeffect.

In the SOP or COP (Step S4), the hydrogen peroxide solution may also besprayed to the content filling station 6 at rest to perform the SOP orCOP (Step S4) of the content filling station 6 in parallel with the CIP(Step S1) thereof.

When the SOP or COP (Step S4) is performed, the temperature of theatmosphere in the chamber 20 is raised by the aseptic hot air blastedinto the chamber 21 described above. As a result, the hydrogen peroxideis activated, the sterilization effect of the SOP or COP (Step S4) isimproved, and any excessive hydrogen peroxide solution is dried andremoved by the aseptic hot air after spraying of the hydrogen peroxidesolution.

(10) The same SOP or COP (Steps S5, S6, S7) as the SOP or COP (Step S2)of the content filling station is performed stepwise on the containersterilizing station 5, the container sealing station 7 and the capsterilizing station 53 in the period from the start of the SOP or COP(Step S2) to the end of the SIP (Step S3) of the content fillingstation.

(11) Steps S5, S6 and S7 can be performed in any order.

Supposing that Step S5 is first performed, a peracetic acid solution issprayed from the injection nozzles 52 to the container sealing station 7during spraying of the aseptic water in Step S2.

In this way, the outer surface of the container sealing station 7 issterilized by the peracetic acid. In addition, since the peracetic acidis blasted to the outer surface of the container sealing station 7 whilethe aseptic water is being blasted to the content filling station 6, theperacetic acid can be prevented from adhering to the outer surface ofthe content filling station 6.

After the peracetic acid is sprayed to the outer surface of thecontainer sealing station 7 in Step S5, aseptic water is sprayed. Inthis way, the peracetic acid is washed from the outer surface of thecontainer sealing station 7, and the SOP or COP of Step S5 is completed.

During Step S5, since the container sealing station 7 is being driven,and the various wheels other than the wheel 9 are rotating, theperacetic acid and the aseptic water as working fluids spread into everycorner of the various kinds of equipment of the container sealingstation 7 to improve the cleaning effect and the sterilization effect.

(12) Step S6 is then performed.

In Step S6, blasting of the peracetic acid solution from the nozzles 50to the container sterilizing station 5 is performed in synchronizationwith blasting of the aseptic water in Step S5, and when the blasting ofthe aseptic water in Step S5 is completed, blasting of the aseptic waterfrom the nozzles 50 to the container sterilizing station 5 is performed.

Since the wheel 12 or the like of the container sterilizing station 5 isbeing driven when the peracetic acid solution and the aseptic water areblasted, the effect of cleaning and sterilization of the outer surfaceof the container sterilizing station 5 is improved.

Since the SOP or COP (Step S6) of the container sterilizing station 5 isperformed in parallel with the SIP (Step S3) of the drink supply piping34, the downtime of the aseptic filling apparatus is reduced, and theproductivity of the bottled drink is improved.

(13) Step S7 is then performed.

In Step S7, blasting of the peracetic acid solution from the nozzles 54to the cap sterilizing station 53 is performed in synchronization withblasting of the aseptic water in Step S6, and when the blasting of theaseptic water in Step S6 is completed, blasting of the aseptic waterfrom the nozzles 54 to the cap sterilizing station 53 is performed.

Since the wheel or the like of the cap sterilizing station 53 is beingdriven when the peracetic acid solution and the aseptic water areblasted, the effect of cleaning and sterilization of the outer surfaceof the cap sterilizing station 53 is improved.

Since the SOP or COP (Step S7) of the cap sterilizing station 53 isperformed in parallel with the SIP (Step S3), the downtime of theaseptic filling apparatus is reduced, and the productivity of thebottled drink is improved.

(14) In this way, the aseptic filling apparatus is decontaminated byperforming the CIP (Step S1), the SIP (Step S3) and the SOP or COP(Steps S2, S4, S5, S6, S7) of the parts of the aseptic filling apparatuswhere contamination is particularly unwanted.

In addition, the aseptic air continues being blasted into the chamber 21to keep the surroundings of the content filling station 7 at a positivepressure. The aseptic air further flows to the container molding station4, the container sterilizing station 5 and the container sealing station7. Thus, the aseptic condition in the chambers 19, 20 and 21 ismaintained.

For the cap sterilizing station 53, the aseptic condition of theatmosphere in the chamber 56 is maintained by blasting aseptic air intothe chamber 56 from another system.

As shown in FIG. 4 , the time required to decontaminate the asepticfilling apparatus by the CIP (Step S1), the SIP (Step S3) and the SOP orCOP (Steps S2, S4, S5, S6, S7) described in (1) to (13) above is aboutthree hours. The time required for decontamination of conventionalaseptic filling apparatuses is about six hours as shown in FIG. 6 , andit can be seen that the downtime is reduced to about half according tothe present invention.

(15) After the CIP (Step S1), the SIP (Step S3) and the SOP or COP(Steps S2, S4, S5, S6, S7) described above are completed, manufacture ofanother kind of bottled drink is started.

Manufacture of another kind of bottled drink will be described.Referring to FIG. 1 , first, the preform 1 is introduced into theheating furnace by the shooter 22 and the wheel 23, and conveyed by theendless chain 24 in the heating furnace.

The preform 1 is heated to a temperature range suitable for molding bythe heater 25 while the preform 1 is conveyed by the endless chain 24 inthe heating furnace.

(16) The heated preform 1 is put in the molding die 8 rotating aroundthe wheel 10, and the molding die 8 is closed. An extension rod (notshown) is lowered into the preform 1 until the extension rod abutsagainst the bottom of the preform 1, and starts expanding the preform 1.In addition, blow molding air is blasted to expand the preform 1 in themolding die 8 into the bottle 3. Once the molding of the bottle 3 in themolding die 8 is completed, the molding die 8 is opened, and thefinished bottle 3 is removed from the molding die 8 by a gripper (notshown) disposed around the wheel 11.

(17) The bottle 3 conveyed from the wheel 11 travels around the wheel 12in the chamber 20 having been subjected to the SOP or COP (Step S6), andmeanwhile, a mist of the sterilizer is blasted to the bottle 3 from thesterilizer spraying nozzle 27 of the container sterilizing station 5.Thus, a coating of the sterilizer is formed on the inner and outersurfaces of the bottle 3, and the inner and outer surfaces of the bottle3 are sterilized.

After that, heated aseptic air is blasted to the bottle 3 from the airrinsing nozzle 28 of the container sterilizing station 5 while thebottle 3 is traveling around the wheel 13. Thus, the sterilizer on theinner and outer surfaces of the bottle 3 is activated to improve thesterilization effect, and any excessive sterilizer is removed.

(18) The sterilized bottle 3 travels in the chamber 21 by being passedbetween the wheels 14, 15, 9, 16, 17 and 18 in the bottle conveyingpath. The SOP or COP (Step S2) in the chamber 21 has already beencompleted, and the aseptic air is constantly being blasted into thechamber 21.

(19) While the bottle 3 is traveling around the wheel 9, the bottle 3 isfilled with a content, such as a drink, from the drink supply piping 34.

The interior of the drink supply piping 34 has already been subjected tocleaning by CIP (Step S1) and sterilization by SIP (Step S3) anddecontaminated.

The bottle 3 is filled with a content, such as a drink, from the fillingnozzle 32 through the decontaminated drink supply piping 34 of thecontent filling station 6.

The content is previously prepared in the preparation apparatus,sterilized and stored in the serve tank 33.

(20) The bottle 3 filled with the drink is passed from the gripper 36 atthe wheel 9 to a gripper at the downstream wheel 16, and then to agripper at the further downstream wheel 17, the mouth portion 3 a of thebottle 3 is closed by the sterilized cap 51 in the container sealingstation 7, and then the bottle 3 is ejected out of the chamber 21.

The cap 51 is previously sterilized in the cap sterilizing station 53before the cap 51 is supplied to the container sealing station 7. Theinterior of the cap sterilizing station 53 has already beendecontaminated by cleaning and sterilization by the SOP or COP (StepsS4, S7) described above.

Manufacture of another kind of aseptic bottled drink is performed asdescribed above.

Second Embodiment

As shown in FIG. 5 , according to a second embodiment, although the CIP(Step S1), SIP (Step S3) and the SOP or COP (steps S2, S5, S6, S7)achieved by spraying a hydrogen peroxide solution are performed as inthe first embodiment, the SOP or COP (Steps S2, S5, S6, S7) achieved byblasting a peracetic acid solution and aseptic water is simultaneouslyperformed on the content filling station 6, the container sealingstation 7, the container sterilizing station 5 and the cap sterilizingstation 53.

Since the SOP or COP (Steps S5, S6, S7) of the container sterilizingstation 5, the container sealing station 7 and the cap sterilizingstation 53 is performed in parallel with the SOP or COP (Step S2) of thecontent filling station 6 in this way, the downtime of the asepticfilling apparatus is further reduced, and the productivity of thebottled drink is further improved.

In addition, when the CIP (Step S1) of the content filling station 6 isperformed, the SOP or COP (Step S4) using hydrogen peroxide of the otherstations such as the container sealing station 7 is performed inparallel therewith. In this process, the wheels 17 and the like of theother stations such as the container sealing station 7 are rotating, sothat the sterilization effect of the other stations such as thecontainer sealing station 7 is improved.

Furthermore, when the SIP (Step S3) of the content filling station 6 isperformed, the SOP or COP (Step S4) using hydrogen peroxide of the otherstations being driven, such as the container sealing station 7, isperformed in parallel therewith. Thus, the sterilization effect of theother stations such as the container sealing station 7 is furtherimproved.

Third Embodiment

According to a third embodiment, as shown in FIG. 7 , the controllingportion (not shown) is programmed to successively perform the CIP, theSIP and the SOP or COP for the content filling station 6.

First, before starting the CIP (Step S1) of the content filling station6, the clutch in the power transmission system of the aseptic fillingapparatus is disconnected to stop rotation of only the wheel 9 in thecontent filling station 6, thereby stopping rotation of the fillingnozzles 32.

As shown in the right half of FIG. 3 , the nozzle mouth 32 a of thefilling nozzle 32 is then closed by the cup 42. In addition, thecoupling 44 is connected. In this way, a circulation path for flowing apredetermined working fluid for the CIP such as a cleaning liquid orsterilizing liquid is formed.

The CIP (Step S1) is then started, and a predetermined working fluidsuch as an alkali cleaner or water is fed from the reservoir tank 38 bythe pump 39 in a predetermined order. The cleaning liquid or the likeflows through the feed pipe 40 from the reservoir tank 38 to the surgetank 33, passes through the drink supply piping 34, flows into the uppermanifold 37 and then to each filling nozzle 32, and eventually returnsto the reservoir tank 38 through the return pipe 41. Thus, the cleaningliquid or the like flows in the circulation path for a predeterminedtime in a predetermined order to clean the interior of the drink supplypiping 34 including the interior of the filling nozzles 32.

As shown in FIG. 8 , the working fluid such as the cleaning liquidcirculates in the drink supply piping 34 for 20 minutes, for example,while the working fluid is heated to about 80° C., for example. In amiddle of the CIP, for example, in a final stage of the CIP, thetemperature of the working fluid is raised to a sterilizationtemperature required for the subsequent SIP, such as 95° C. Theoperating temperature range is preferably from 80° C. to 99° C. Thecleaning liquid used from the middle of the CIP is preferably water,because the cleaning liquid is used also for rinsing of the cleaningliquid. The temperature of the working fluid may be raised to thesterilization temperature at the start of the CIP.

Following the CIP (Step S1) is completed, the SIP (Step S2) of thecontent filling station 6 is performed with rotation of the wheel 9 ofthe content filling station 6 kept stopped.

The SIP is performed by passing the working fluid such as water used inthe CIP described above through the drink supply piping 34 while keepingthe temperature of the working fluid at a temperature required forsterilization. As shown in FIG. 8 , the working fluid circulates in thedrink supply piping 34 for 10 minutes, for example, while the workingfluid is heated to about 95° C., for example. Thus, the interior of thedrink supply piping 34 is sterilized. In the case of SIP serving asrinsing, hot water does not circulate but is fed in one direction.

After the interior of the drink supply piping 34 is sterilized, as shownin FIG. 8 , the water passing through the piping is gradually cooled toroom temperature.

As described above, since the temperature of the cleaning liquid israised to a temperature required for the SIP (Step S2) following the CIP(Step S1) in an early or middle stage of the CIP (Step S1), so that theSIP (Step S2) can be started immediately after the CIP (Step S1), thedowntime can be reduced.

After the SIP (Step S2) is completed, the SOP or COP (Step S3) of thecontent filling station 6 is performed.

In FIG. 3 , reference numeral 45 denotes an injection nozzle for the SOPor COP (Step S3) arranged to be opposed to each of different parts ofthe content filling station 6 in the chamber 21. The injection nozzles45 are fixed to the interior of the chamber 21 at predeterminedlocations.

Reference numeral 46 denotes a reservoir tank, which is a supply sourceof a predetermined working fluid, such as a liquid chemical agent suchas an alkali cleaning liquid, a peracetic acid cleaning liquid or ahydrogen peroxide solution, or aseptic water. The reservoir tank 46 isprovided for each of different liquid chemical agents such as a hydrogenperoxide solution or aseptic water, although only one reservoir tank 46is shown for convenience of drawing. Reference numerals 47 and 48 denotesupply pipes extending from each reservoir tank 46 to the injectionnozzle 32 described above. Each of the supply pipes 47 and 48 isprovided with a pump 49.

Alternatively, the pumps 39, 49 and the like may be omitted, and thereservoir tanks 38 and 46 may be located at high elevations so that thecleaning liquid, liquid chemical agent or the like can be supplied intothe chamber 21 or the like under hydrostatic pressure.

When the SIP (Step S2) of the interior of the drink supply piping 34 inthe content filling station 6 is completed, and the coupling 44 isdisconnected, the clutch described above is connected, so that the wheel9 is allowed to rotate in association with the other wheels 13, 17 andthe like. Alternatively, the wheel 9 is allowed to rotate by beingdriven by the dedicated servo motor for the wheel 9.

When the wheel 9 starts rotating, the SOP or COP (Step S3) in thechamber 21 is started at the same time.

The SOP or COP (Step S3) of the content filling station 6 in the chamber21 is performed by blasting the sterilizer such as a peracetic acidsolution from the injection nozzles 45 to the exterior of the contentfilling station 6 and then blasting aseptic water from the sameinjection nozzles 45. The sterilizer blasted to the content fillingstation 6 sterilizes the outer surface of the content filling station 6,and the aseptic water subsequently blasted washes the remainder of thedrink in the previous filling operation and the sterilizer such asperacetic acid from the surface of the content filling station 6.

During the SOP or COP (Step S3), the filling nozzles 32 or the likerotate with the wheel 9. Since the working fluid is blasted to therotating content filling station 6, foreign matters or the like areefficiently washed from the outer surface of the filling nozzles 32,which have a particularly complicated shape and structure, and thesurface of the filling nozzles 32 is efficiently sterilized.

In the period from the start of the CIP (Step S1) to the end of the lastSOP or COP (Step S7) described later, aseptic air, desirably aseptic hotair, supplied from the aseptic air supply source described above isconstantly blasted to the content filling station 6 in the chamber 21.This ensures that the atmosphere in the chamber 21 is kept at a positivepressure, and the outside air containing bacteria, dust or the like isprevented from entering the chamber 21. Furthermore, the aseptic airalso flows to the container sealing station 7 in the same chamber 21 andthe container sterilizing station 5 in the chamber 20, so that theoutside air is also prevented from entering the container sealingstation 7 and the like.

The decontaminating apparatuses for the container molding station 4, thecontainer sealing station 7, the container sterilizing station 5 and thecap sterilizing station 53 will be now described. In order to performone or both of the SOP and COP (Steps S4, S5, S6, S7) of the stations 4,7, 5 and 53, as shown in FIG. 1 , injections nozzles 57 having the samestructure as the injection nozzles 45 are arranged at locations in thechamber 19 so as to be opposed to the container molding station 4,injection nozzles 52 having the same structures as the injection nozzles45 are arranged at locations in the chamber 21 so as to be opposed tothe container sealing station 7, injection nozzles 50 having the samestructures as the injection nozzles 45 are arranged at locations in thechamber 20 so as to be opposed to the container sterilizing station 5,and injection nozzles 54 having the same structure as the injectionnozzles 45 are arranged at locations in the chamber 56 so as to beopposed to the cap sterilizing station 53.

Supply pipes (not shown) extend from the reservoir tank 46 to theinjection nozzles 57, 52, 50 and 54, and the supply pipes are alsoprovided with a pump (not shown) that feeds a liquid chemical agent orthe like to these pipes under pressure.

As shown in FIG. 7 , the controlling portion (not shown) is programmedto perform the SOP or COP (Steps S4, S5, S6, S7) of the containermolding station 4, the container sealing station 7, the containersterilizing station 5 and the cap sterilizing station 53 from the startof the CIP (Step S1) of the content filling station 6. In addition, thecontrolling portion is programmed to perform two types of SOP (Steps S4,S5, S6, S7) on each station.

As shown in FIG. 7 , the SOP performed first (Step S4) is performed insynchronization with one or both of the CIP (Step S1) and the SIP (StepS2) of the content filling station 6 and performed simultaneously forall of the container molding station 4, the container sealing station 7,the container sterilizing station 5 and the cap sterilizing station 53.

The SOP or COP (Step S4) is different from the SOP or COP (Step S3) ofthe content filling station 6 and is performed by spraying a hydrogenperoxide solution from the injection nozzles 57, 50, 52 and 54 to theouter surface of the container molding station 4, the containersterilizing station 5, the container sealing station 7 and the capsterilizing station 53. In the SOP or COP (Step S4), the hydrogenperoxide solution may be sprayed from the injection nozzles 45 to thecontent filling station 6 at the same time and dried and vaporized byaseptic hot air.

In the SOP or COP (Step S4), the hydrogen peroxide solution serving as aworking fluid is blasted to each of the stations 4, 5, 7 and 53 whilethe wheels 10, 12, 13 and the like other than the wheel 9 are rotating,so that the sterilization effect of the stations 4, 5, 7 and 53 isimproved.

That is, in the CIP (Step S1), although the clutch is disconnected tostop the wheel 9 of the content filling station 6 as described above,the other wheels 17 and the like can rotate. In the alternative case,even if the dedicated servo motor for the wheel 9 of the content fillingstation 6 is stopped, the other wheels 17 and the like can rotate bybeing driven by the respective dedicated servo motors. Thus, even if thewheel 9 of the content filling station 6 is stopped when the CIP (StepS1) of the content filling station 6 is performed, the other wheels 17of the other stations such as the container sterilizing station 5 canrotate, so that the SOP or COP (Step S4) of the outer surface of thestations other than the content filling station 6, that is, thecontainer molding station 4, the container sterilizing station 5, thecontainer sealing station 7 and the cap sterilizing station 53, can beeffectively performed.

The sterilizer used for the SOP effectively contains 1% by mass or moreof hydrogen peroxide. Alternatively, the sterilizer may contain one ormore of ethanol, peracetic acid, acetic acid, octanoic acid,peroxyoctanoic acid, ozone, chlorine dioxide, chlorinated alkali andsodium hypochlorite or a mixture thereof. The sterilizer may be gas ormist, rather than liquid.

When the SOP or COP (Step S4) is performed, if aseptic hot air has beenblasted into the chambers 19, 20, 21 and 56 before spraying the hydrogenperoxide solution, the temperature of the atmosphere in the chambers 19,20, 21 and 56 increases, so that the hydrogen peroxide is activated, andthe effect of sterilization by the SOP or COP (Step S4) is improved.After spraying of the hydrogen peroxide solution, the aseptic hot airpromotes drying and removal of any excessive hydrogen peroxide solution.

The SOP or COP (Steps S5, S6, S7) of the container sealing station 7,the container sterilizing station 5 and the cap sterilizing station 53that follows the SIP (Step S2) described above is the same as the SOP orCOP (Step S3) of the content filling station 6 and is performed stepwisealong with the SOP or COP (Step S3) of the content filling station 6.

In the SOP or COP (Steps S5, S6, S7), a peracetic acid solution is firstblasted stepwise from the injection nozzles 52, 50 and 54 to thecontainer sealing station 7, the container sterilizing station 5 and thecap sterilizing station 53 to sterilize the outer surface of thestations 7, 5 and 53.

Once the injection of the hydrogen peroxide solution is completed,aseptic water is blasted stepwise to the outer surface of stations 7, 5and 53. In this way, the remainder of the drink in the previous filling,the remainder of the peracetic acid solution and the like are washedfrom the surface of the stations 7, 5 and 53.

A shortage of supply of the sterilizer such as peracetic acid and theaseptic water can be prevented by injecting the hydrogen peroxidesolution and the aseptic water stepwise in the SOP (or COP) as describedabove.

When the SOP (Step S3) of the content filling station 6 is performed,the wheel 9 of the content filling station 6 can rotate, and the otherwheels 12, 13 and the like of the container sealing station 7, thecontainer sterilizing station 5 and the cap sterilizing station 53 canalso rotate. Thus, in the period from the SOP or COP (Step S3) of thecontent filling station 6 to the SOP (Step S7) of another station, thecleaning effect of the stations 6, 7, 5 and 53 by blasting of peraceticacid or aseptic water as a working fluid is improved.

When the SOP or COP (Steps S3, S5, S6, S7) is performed, the aseptic hotair is also blasted into the chambers 21, 20 and 56.

When the SOP or COP (Steps S5, S6, S7) is performed, if the sterilizeror cleaning liquid such as peracetic acid comes into contact with thefilling valves 32, heat of the filling valves 32 is lost, and thus thefilling valves 32 can be poorly sterilized. To avoid this, a partitionwall that prevents the sterilizer or cleaning liquid from flowing to thecontent filling station 6 is preferably provided between the contentfilling station 6 and the other stations.

Alternatively, gas or mist of the sterilizer, rather than thesterilizing liquid, is preferably used as a sterilizer for the SOP orCOP in the other chambers.

Next, operations of the aseptic filling apparatus described above and amethod of decontaminating the aseptic filling apparatus will bedescribed.

(1) First, a decontamination operation of the aseptic filling apparatuswill be described with reference to the flowchart of FIG. 7 .

When manufacture of the bottled drink is finished, and manufacture ofanother kind of bottled drink is started by changing the kind of drink,the CIP (Step S1), the SIP (Step S2) and the SOP or COP (Steps S3, S4,S5, S6, S7) are performed on the aseptic filling apparatus.

In the period from the start of the CIP (Step S1) to the end of the lastSOP (Step S7), aseptic hot air is preferably constantly blasted to thecontent filling station 6 in the chamber 21. This ensures that theatmosphere in the chamber 21 is kept at a positive pressure, and theoutside air containing bacteria, dust or the like is prevented fromentering the chamber 21. The aseptic air also flows to the containersealing station 7 in the same chamber 21 and the container sterilizingstation 5 in the chamber 20, so that contamination of the containersealing station 7 and the like is also prevented. Aseptic air is alsosupplied into the chamber 56 for the cap sterilizing station 53.

(2) Before starting the CIP (Step S1) of the content filling station 6,the clutch in the power transmission system of the aseptic fillingapparatus is disconnected to stop rotation of only the wheel 9 of thecontent filling station 6, thereby stopping rotation of the fillingnozzles 32. In addition, the surge tank 33 is emptied.

(3) As shown in the right half of FIG. 3 , the nozzle mouth 32 a of thefilling nozzle 32 is closed by the cup 42. In addition, the coupling 44is connected. In this way, a circulation path for flowing apredetermined working fluid for the CIP (Step S1) such as a cleaningliquid or sterilizing liquid is formed.

(4) The CIP (Step S1) is started, and a predetermined working fluid suchas an alkali cleaning liquid or water is fed from the reservoir tank 38by the pump 39 in a predetermined order. The cleaning liquid or the likeflows through the feed pipe 40 from the reservoir tank 38 to the surgetank 33, passes through the drink supply piping 34, flows into the uppermanifold 37 and then to each filling nozzle 32, and eventually returnsto the reservoir tank 38 through the return pipe 41. Thus, the cleaningliquid or the like flows in the circulation path for a predeterminedtime in a predetermined order to clean the interior of the drink supplypiping 34 including the interior of the filling nozzles 32.

As shown in FIG. 8 , from a middle of the CIP (Step S1), the watercirculating in the drink supply piping 34 at a temperature of 80° C.,for example, is heated to a temperature required for sterilization inthe subsequent SIP (Step S2), such as 95° C. This is the end of the CIP(Step S1).

(5) After the CIP (Step S1) is completed, the SIP (Step S2) of thecontent filling station 6 is performed while rotation of the wheel 9 inthe content filling station 6 is kept stopped. The SIP (Step S2) isperformed by passing the hot water at 95° C. described above through thedrink supply piping 34. The hot water passing through the drink supplypiping 34 sterilizes the interior of the drink supply piping 34including the filling nozzles 32 and the like and, at the same time,removes any remaining cleaning liquid or waste liquid in the CIP (StepS1) from the interior of the drink supply piping 34. Removal of thewaste liquid or the like from the interior of the drink supply piping 34is achieved by collecting the waste liquid or the like in the reservoirtank 38 and then drawing the waste liquid from the reservoir tank 38,for example.

As described above, since the SIP (Step S2) is started immediately afterthe CIP (Step S1) by raising the temperature of the working fluid duringthe cleaning step using a chemical agent such as an alkali or therinsing step using hot water after the cleaning with the chemical agent,the idle time between the end of filling with a drink and the start offilling with another drink is reduced, as is obvious from comparisonbetween FIGS. 8 and 12 .

Conditions of the temperature of the hot water used in the SIP (Step S2)and the duration of the SIP (Step S2) are determined based on theconditions required for sterilization of the content of the product. Forexample, in the case of a product having a pH lower than 4, thetemperature is at least 60° C., and the duration is 10 minutes, in thecase of a product having a pH of 4.0 to 4.6, the temperature is 85° C.,and the duration is 30 minutes, and in the case of a product having a pHequal to or higher than 4.6, the temperature is 120° C., and theduration is equal to or longer than 4 minutes (typically, thetemperature is 130° C., and the duration is equal to or longer than 30minutes). In the case where the SIP (Step S2) requires a temperatureequal to or higher than 100° C., a vapor can also be used in addition tothe hot water.

(6) When one or both of the CIP (Step S1) and the SIP (Step S2) of thedrink supply piping 34 of the content filling station 6 is performed,the SOP or COP (Step S4) is performed in parallel therewith on (i) theouter surface of various kinds of equipment in the container moldingstation 4 in the chamber 19, (ii) the outer surface of various kinds ofequipment in the container sterilizing station 5 in the chamber 20,(iii) the outer surface of various kinds of equipment in the containersealing station 7 in the chamber 21, and (iv) the outer surface ofvarious kinds of equipment in the chamber 56 for the cap sterilizingstation 53.

In this process, the wheel 9 of the content filling station 6 isstopped, while the equipment, such as the wheels 10, 12, 13, 17 and 18,in the container molding station 4, the container sterilizing station 5,the container sealing station 7 and the cap sterilizing station 53 arebeing driven.

The SOP or COP (Step S4) is different from the SOP or COP (Steps S3 toS7) of the content filling station 6 and the other stations, and ahydrogen peroxide solution is blasted from the injection nozzles 57, 50,52 and 54 to the outer surface of the container molding station 4, thecontainer sterilizing station 5, the container sealing station 7 and thecap sterilizing station 53.

In this process, since the container molding station 4, the containersterilizing station 5, the container sealing station 7 and the capsterilizing station 53 are being driven, the hydrogen peroxide solutionas a working fluid spreads into every corner of the various kinds ofequipment thereof to improve the cleaning effect and the sterilizationeffect.

(7) In the SOP or COP (Step S4) of the other stations such as thecontainer molding station 4, the hydrogen peroxide solution may also besprayed from the injection nozzle 45 to the content filling station 6 atrest to perform the SOP or COP (Step S3) of the content filling station6 in parallel with the one or both of the CIP (Step S1) and the SIP(Step S2).

By spraying hydrogen peroxide at the same time as the CIP (Step S1), theouter surface of the filling nozzles 32, which have a complicated shape,can be efficiently sterilized. More specifically, even when thetemperature of the filling nozzles 32 is 130° C., if the interior of thechamber 21 is dry, it is difficult to sterilize heat-resistantspore-forming bacteria because the sterilization is dry heatsterilization. However, as is obvious from FIG. 10 , which shows aresult of an experiment by the inventors, the outer surface of thefilling valves can be easily sterilized, provided that the concentrationof the hydrogen peroxide gas in the chamber 21 is equal to or higherthan 5 mg/L, and the temperature of the filling valves is equal to orhigher than 60° C.

When the SOP or COP (Step S4) is performed, the temperature of theatmosphere in the chamber 20 is raised by the aseptic hot air blastedinto the chamber 21 described above. As a result, the hydrogen peroxideis activated, the sterilization effect of the SOP or COP (Step S4) isimproved, and any excessive hydrogen peroxide solution is dried andremoved by the aseptic hot air after spraying of the hydrogen peroxidesolution.

(8) When the SIP (Step S2) of the interior of the drink supply piping 34in the content filling station 6 is completed, and the coupling 44 isdisconnected, the clutch described above is connected, so that the wheel9 is allowed to rotate in association with the other wheels 13, 17 andthe like. Alternatively, the wheel 9 is allowed to rotate by beingdriven by the dedicated servo motor for the wheel 9.

When the wheel 9 or the like starts rotating, the same SOP or COP (StepsS3, S5, S6, S7) is performed stepwise on the content filling station 6,the container sterilizing station 5, the container sealing station 7,the cap sterilizing station 53 and the container molding station 4.Steps S3, S5, S6 and S7 can be performed in any order.

(9) Supposing that Step S3 is first performed, a peracetic acid solutionis sprayed from the injection nozzles 54 to the content filling station6 during spraying of the aseptic water in Step S3.

When Step S3 is started, the wheel 9 of the content filling station 6starts rotating along with the other wheels, and thus the fillingnozzles 32 also start rotating.

Once Step S3 is performed on the content filling station 6, apredetermined working fluid such as a liquid chemical agent or asepticwater is sprayed from the injection nozzles 45 to the exterior of thecontent filling station 6 in a predetermined order. Since the workingfluid is blasted to the rotating filling nozzles 32 and the like, theouter surface of the filling nozzles 32 and the like is efficientlycleaned and sterilized.

The SOP or COP of Step S3 may be a process of deactivating bacteria byusing warm water or the like of a temperature equal to or higher than60° C. and lower than 100° C. instead of the sterilizer.

In Step S3, the peracetic acid solution as a sterilizer is first blastedfrom the injection nozzles 45 to the content filling station 6 tosterilize the outer surface of the content filling station 6, andaseptic water is then blasted to wash any excessive peracetic acid as asterilizer or dirt from the surface of the content filling station 6.

(10) Supposing that Steps S5 to S7 are then successively performed,injection of the peracetic acid solution in Steps S5 to S7 is performedstepwise at predetermined time intervals after the start of theinjection of the peracetic acid solution in Step S3. This ensures thatan appropriate amount of peracetic acid is blasted without shortage ofsupply thereof to each of the content filling station 6, the containersterilizing station 5, the container sealing station 7, the capsterilizing station 53 and the container molding station 4.

(11) Once the injection of the hydrogen peroxide solution in Steps S5 toS7 is completed, aseptic water is then successively blasted in steps S3,S5, S6 and S7 to the content filling station 6, the containersterilizing station 5, the container sealing station 7 and the containermolding station 4 in this order. This ensures that an appropriate amountof aseptic water is supplied without shortage of supply thereof to eachof the content filling station 6, the container sterilizing station 5,the container sealing station 7, the cap sterilizing station 53 and thecontainer molding station 4.

(11) In this way, the aseptic filling apparatus is decontaminated byperforming the CIP (Step S1), the SIP (Step S2) and the SOP or COP(Steps S3, S4, S5, S6, S7) of the parts of the aseptic filling apparatuswhere contamination is particularly unwanted.

In addition, the aseptic air continues being blasted into the chamber 21to keep the surroundings of the content filling station 7 at a positivepressure. The aseptic air further flows to the container molding station4, the container sterilizing station 5 and the container sealing station7. Thus, the aseptic condition in the chambers 19, 20 and 21 ismaintained.

For the cap sterilizing station 53, the aseptic condition of theatmosphere in the chamber 56 is maintained by blasting aseptic air intothe chamber 56 from another system.

As shown in FIG. 7 , the time required to decontaminate the asepticfilling apparatus by the CIP (Step S1), the SIP (Step S2) and the SOP orCOP (Steps S3, S4, S5, S6, S7) described in (1) to (11) above is aboutfour hours. The time required for decontamination of conventionalaseptic filling apparatuses is about six hours as shown in FIG. 11 , andit can be seen that the downtime is reduced according to the presentinvention.

(12) After the CIP (Step S1), the SIP (Step S2) and the SOP or COP(Steps S3, S4, S5, S6, S7) described above are completed, manufacture ofanother kind of bottled drink is started.

The method of manufacturing another kind of bottled drink is the same asthose according to the first and second embodiments described above, anddetailed descriptions thereof will be omitted.

Fourth Embodiment

As shown in FIG. 9 , according to a fourth embodiment, the CIP (StepS1), the SIP (Step S2) and the SOP or COP (Step S4) achieved by sprayinga hydrogen peroxide solution are performed as in the second embodiment,the SOP or COP (Steps S3, S5, S6, S7) achieved by blasting a peraceticacid solution and aseptic water is also performed stepwise on thecontent filling station 6, the container sealing station 7, thecontainer sterilizing station 5 and the cap sterilizing station 53.

However, steps S3, S5, S6 and S7 are different from those in the thirdembodiment in the following points.

That is, as shown in FIG. 9 , a peracetic acid solution is first blastedstepwise from the injection nozzles 45, 52, 50 and 54 to the contentfilling station 6, the container sealing station 7, the containersterilizing station 5 and the cap sterilizing station 53 to sterilizethe outer surface of the stations 7, 5 and 53, and aseptic water is thenblasted stepwise to the stations 7, 5 and 53 to wash the remainder ofthe drink in the previous filling any excessive hydrogen peroxidesolution or the like from the surface of the stations. In this process,cleaning with aseptic water in each preceding SOP or COP and cleaningwith peracetic acid in the subsequent SOP or COP are performed in atemporally overlapped manner. This ensures that peracetic acid suppliedin each SOP or COP is prevented from adhering to a part where peraceticacid supplied in the preceding SOP or COP is being washed and removed.

As described above, the SOP or COP (Steps S3, S5, S6, S7) of the contentfilling station 6, the container sterilizing station 5, the containersealing station 7 and the cap sterilizing station 53 is performedstepwise in such a manner that cleaning with aseptic water and cleaningwith peracetic acid are performed in an overlapped manner, so that thedowntime of the aseptic filling apparatus is further reduced, and theproductivity of the bottled drink is further improved.

Fifth Embodiment

As shown in FIG. 10 , according to a fifth embodiment, although the CIP(Step S1), the SIP (Step S2) and the SOP or COP (Steps S3, S5, S6, S7)achieved by spraying a hydrogen peroxide solution are performed as inthe third embodiment, the SOP or COP (Steps S3, S5, S6, S7) achieved byblasting a peracetic acid solution and aseptic water is simultaneouslyperformed on the content filling station 6, the container sealingstation 7, the container sterilizing station 5 and the cap sterilizingstation 53.

Since the SOP or COP (Steps S5, S6, S7) of the container sterilizingstation 5, the container sealing station 7 and the cap sterilizingstation 53 is performed in parallel with the SOP or COP (Step S3) of thecontent filling station 6 in this way, the downtime of the asepticfilling apparatus is further reduced, and the productivity of thebottled drink is further improved.

In addition, when one or both of the CIP (Step S1) and the SIP (Step S2)of the content filling station 6 is performed, the SOP or COP (Step S4)using hydrogen peroxide of the other stations such as the containersealing station 7 is performed in parallel therewith. In this process,the wheels 17 and the like of the other stations such as the containersealing station 7 are rotating, so that the sterilization effect of theother stations such as the container sealing station 7 is improved.

Sixth Embodiment

According to a sixth embodiment, as shown in FIG. 14 , the controllingportion (not shown) is programmed to successively perform the SIP andthe SOP or COP on the content filling station 6.

First, before starting the SIP (Step S1) of the content filling station6, the clutch in the power transmission system of the aseptic fillingapparatus is disconnected to stop rotation of only the wheel 9 in thecontent filling station 6, thereby stopping rotation of the fillingnozzles 32.

As shown in the right half of FIG. 3 , the nozzle mouth 32 a of thefilling nozzle 32 is then closed by the cup 42. In addition, thecoupling 44 is connected. In this way, a circulation path for flowing apredetermined working fluid for the SIP such as a cleaning liquid,sterilizing liquid or water is formed.

The SIP (Step S1) is then started, and a predetermined working fluidsuch as an alkali cleaning liquid or water is fed from the reservoirtank 38 by the pump 39 in a predetermined order. The cleaning liquid orthe like flows through the feed pipe 40 from the reservoir tank 38 tothe surge tank 33, passes through the drink supply piping 34, flows intothe upper manifold 37 and then to each filling nozzle 32, and eventuallyreturns to the reservoir tank 38 through the return pipe 41. Thus, thecleaning liquid or the like flows in the circulation path for apredetermined time in a predetermined order to clean and sterilize andthus decontaminate the interior of the drink supply piping 34 includingthe interior of the filling nozzles 32.

As shown in FIG. 15 , the working fluid such as the cleaning liquidcirculates in the drink supply piping 34 for 20 minutes, for example,while the working fluid is heated to about 95° C., for example. From amiddle of the SIP, water is used as a cleaning liquid, which is aworking fluid. The circulating working fluid cleans and sterilizes theinterior of the drink supply piping 34.

After the interior of the drink supply piping 34 is sterilized, as shownin FIG. 15 , the water passing through the piping is gradually cooled toroom temperature.

As described above, the interior of the piping is sterilized and cleanedin the SIP (Step S1). Thus, the SIP (Step S1) serves also as the CIP, sothat the conventional CIP can be omitted to substantially reduce thedowntime.

Immediately after completion of the SIP (Step S1), the SOP or COP (StepS2) of the content filling station 6 is performed. The temperaturerequired for the SIP can be a temperature and a duration that allow asterilization value required for sterilization of the drink, which isthe content of the product, to be achieved.

In FIG. 3 , reference numeral 45 denotes an injection nozzle for the SOPor COP (Step S2) arranged to be opposed to each of different parts ofthe content filling station 6 in the chamber 21. The injection nozzles45 are fixed to the interior of the chamber 21 at predeterminedlocations.

Reference numeral 46 denotes a reservoir tank, which is a supply sourceof a predetermined working fluid, such as a liquid chemical agent suchas an alkali cleaning liquid, a peracetic acid cleaning liquid or ahydrogen peroxide solution, or aseptic water. The reservoir tank 46 isprovided for each of different liquid chemical agents such as a hydrogenperoxide solution or aseptic water, although only one reservoir tank 46is shown for convenience of drawing. Reference numerals 47 and 48 denotesupply pipes extending from each reservoir tank 46 to the injectionnozzle 32 described above. Each of the supply pipes 47 and 48 isprovided with a pump 49.

Alternatively, the pumps 39, 49 and the like may be omitted, and thereservoir tanks 38 and 46 may be located at high elevations so that thecleaning liquid, liquid chemical agent or the like can be supplied intothe chamber 21 or the like under hydrostatic pressure.

When the SIP (Step S1) of the interior of the drink supply piping 34 inthe content filling station 6 is completed, and the coupling 44 isdisconnected, the clutch described above is connected, so that the wheel9 is allowed to rotate in association with the other wheels 13, 17 andthe like. Alternatively, the wheel 9 is allowed to rotate by beingdriven by the dedicated servo motor for the wheel 9.

When the wheel 9 starts rotating, the SOP or COP (Step S2) in thechamber 21 is started.

The SOP or COP (Step S2) of the content filling station 6 in the chamber21 is performed by blasting the sterilizer such as a peracetic acidsolution from the injection nozzles 45 to the exterior of the contentfilling station 6 and then blasting aseptic water from the sameinjection nozzles 45. The sterilizer blasted to the content fillingstation 6 sterilizes the outer surface of the content filling station 6,and the aseptic water subsequently blasted washes the remainder of thedrink in the previous filling operation and the sterilizer such asperacetic acid from the surface of the content filling station 6.

During the SOP or COP (Step S2), the filling nozzles 32 or the likerotate with the wheel 9. Since the working fluid is blasted to therotating content filling station 6, foreign matters or the like areefficiently washed from the outer surface of the filling nozzles 32,which have a particularly complicated shape and structure, and thesurface of the filling nozzles 32 is efficiently sterilized.

In the period from the start of the SIP (Step S1) to the end of the lastSOP or COP (Step S6) described later, aseptic air, desirably aseptic hotair, supplied from the aseptic air supply source described above isconstantly blasted to the content filling station 6 in the chamber 21.This ensures that the atmosphere in the chamber 21 is kept at a positivepressure, and the outside air containing bacteria, dust or the like isprevented from entering the chamber 21. Furthermore, the aseptic airalso flows to the container sealing station 7 in the same chamber 21 andthe container sterilizing station 5 in the chamber 20, so that theoutside air is also prevented from entering the container sealingstation 7 and the like.

The decontaminating apparatuses for the container molding station 4, thecontainer sealing station 7, the container sterilizing station 5 and thecap sterilizing station 53 will be now described. In order to performone or both of the SOP and COP (Steps S4, S5, S6) of the stations 4, 7,5 and 53, as shown in FIG. 1 , injections nozzles 57 having the samestructure as the injection nozzles 45 are arranged at locations in thechamber 19 so as to be opposed to the container molding station 4,injection nozzles 52 having the same structures as the injection nozzles45 are arranged at locations in the chamber 21 so as to be opposed tothe container sealing station 7, injection nozzles 50 having the samestructures as the injection nozzles 45 are arranged at locations in thechamber 20 so as to be opposed to the container sterilizing station 5,and injection nozzles 54 having the same structure as the injectionnozzles 45 are arranged at locations in the chamber 56 so as to beopposed to the cap sterilizing station 53.

Supply pipes (not shown) extend from the reservoir tank 46 to theinjection nozzles 57, 52, 50 and 54, and the supply pipes are alsoprovided with a pump (not shown) that feeds a liquid chemical agent orthe like to these pipes under pressure.

As shown in FIG. 14 , the controlling portion (not shown) is programmedto perform the SOP or COP (Steps S3, S4, S5, S6) of the containermolding station 4, the container sealing station 7, the containersterilizing station 5 and the cap sterilizing station 53 from the startof the SIP (Step S1) of the content filling station 6. In addition, thecontrolling portion is programmed to perform two types of SOP (Steps S3,S4, S5, S6) on each station.

As shown in FIG. 14 , the SOP performed first (Step S3) is performed insynchronization with the SIP (Step S1) of the content filling station 6and performed simultaneously for all of the container molding station 4,the container sealing station 7, the container sterilizing station 5 andthe cap sterilizing station 53.

The SOP or COP (Step S3) is different from the SOP or COP (Step S2) ofthe content filling station 6 and is performed by spraying a hydrogenperoxide solution from the injection nozzles 57, 50, 52 and 54 to theouter surface of the container molding station 4, the containersterilizing station 5, the container sealing station 7 and the capsterilizing station 53. In the SOP or COP (Step S3), the hydrogenperoxide solution may be sprayed from the injection nozzles 45 to thecontent filling station 6 at the same time and dried and vaporized byaseptic hot air.

In the SOP or COP (Step S3), the hydrogen peroxide solution serving as aworking fluid is blasted to each of the stations 4, 5, 7 and 53 whilethe wheels 10, 12, 13 and the like other than the wheel 9 are rotating,so that the sterilization effect of the stations 4, 5, 7 and 53 isimproved.

That is, in the SIP (Step S1), although the clutch is disconnected tostop the wheel 9 of the content filling station 6 as described above,the other wheels 17 and the like can rotate. In the alternative case,even if the dedicated servo motor for the wheel 9 of the content fillingstation 6 is stopped, the other wheels 17 and the like can rotate bybeing driven by the respective dedicated servo motors. Thus, even if thewheel 9 of the content filling station 6 is stopped when the SIP (StepS1) of the content filling station 6 is performed, the other wheels 17and the like of the other stations such as the container sterilizingstation 5 can rotate, so that the SOP or COP (Step S3, S4, S5, S6) ofthe outer surface of the stations other than the content filling station6, that is, the container molding station 4, the container sterilizingstation 5, the container sealing station 7 and the cap sterilizingstation 53, can be effectively performed.

The sterilizer used for the SOP effectively contains 1% by mass or moreof hydrogen peroxide. Alternatively, the sterilizer may contain one ormore of ethanol, peracetic acid, acetic acid, octanoic acid,peroxyoctanoic acid, ozone, chlorine dioxide, chlorinated alkali andsodium hypochlorite or a mixture thereof. The sterilizer may be gas ormist, rather than liquid.

When the SOP or COP (Step S3) is performed, if aseptic hot air has beenblasted into the chambers 19, 20, 21 and 56 before spraying the hydrogenperoxide solution, the temperature of the atmosphere in the chambers 19,20, 21 and 56 increases, so that the hydrogen peroxide is activated, andthe effect of sterilization by the SOP or COP (Step S3) is improved.After spraying of the hydrogen peroxide solution, the aseptic hot airpromotes drying and removal of any excessive hydrogen peroxide solution.

The SOP or COP (Steps S4, S5, S6) of the container sealing station 7,the container sterilizing station 5 and the cap sterilizing station 53that follows the SIP (Step S1) described above is the same as the SOP orCOP (Step S2) of the content filling station 6 and is performed stepwisealong with the SOP or COP (Step S2) of the content filling station 6.

In the SOP or COP (Steps S4, S5, S6), a peracetic acid solution is firstblasted stepwise from the injection nozzles 52, 50 and 54 to thecontainer sealing station 7, the container sterilizing station 5 and thecap sterilizing station 53 to sterilize the outer surface of thestations 7, 5 and 53.

Once the injection of the hydrogen peroxide solution is completed,aseptic water is similarly blasted stepwise to the outer surface ofstations 7, 5 and 53. In this way, the remainder of the drink in theprevious filling, the remainder of the peracetic acid solution and thelike are washed from the surface of the stations 7, 5 and 53.

A shortage of supply of the sterilizer such as peracetic acid and theaseptic water can be prevented by injecting the hydrogen peroxidesolution and the aseptic water stepwise in the SOP (or COP) as describedabove.

When the SOP (Step S2) of the content filling station 6 is performed,the wheel 9 of the content filling station 6 can rotate, and the otherwheels 12, 13 and the like of the container sealing station 7, thecontainer sterilizing station 5 and the cap sterilizing station 53 canalso rotate. Thus, in the period from the SOP or COP (Step S2) of thecontent filling station 6 to the SOP (Step S6) of another station, thecleaning effect of the stations 6, 7, 5 and 53 by blasting of peraceticacid or aseptic water as a working fluid is improved.

When the SOP or COP (Steps S2, S4, S5, S6) is performed, the aseptic hotair is also blasted into the chambers 21, 20 and 56.

When the SOP or COP (Steps S2, S4, S5, S6) is performed, if thesterilizer or cleaning liquid such as peracetic acid comes into contactwith the filling valves 32, heat of the filling valves 32 is lost, andthus the filling valves 32 can be poorly sterilized. To avoid this, apartition wall that prevents the sterilizer or cleaning liquid fromflowing to the content filling station 6 is preferably provided betweenthe content filling station 6 and the other stations. Alternatively, gasor mist of the sterilizer, rather than the sterilizing liquid, ispreferably used for the SOP or COP in the other chambers.

Next, operations of the aseptic filling apparatus described above and amethod of decontaminating the aseptic filling apparatus will bedescribed.

(1) First, a decontamination operation of the aseptic filling apparatuswill be described with reference to the flowchart of FIG. 14 .

When manufacture of the bottled drink is finished, and manufacture ofanother kind of bottled drink is started by changing the kind of drink,the SIP (Step S1) serving also as a CIP and the SOP or COP (Steps S2,S3, S4, S5, S6) are performed on the aseptic filling apparatus.

In the period from the start of the SIP (Step S1) to the end of the lastSOP (Step S6), aseptic hot air is preferably constantly blasted to thecontent filling station 6 in the chamber 21. This ensures that theatmosphere in the chamber 21 is kept at a positive pressure, and theoutside air containing bacteria, dust or the like is prevented fromentering the chamber 21. The aseptic air also flows to the containersealing station 7 in the same chamber 21 and the container sterilizingstation 5 in the chamber 20, so that contamination of the containersealing station 7 and the like is also prevented. Aseptic air is alsosupplied into the chamber 56 for the cap sterilizing station 53.

(2) Before starting the SIP (Step S1) of the content filling station 6,the clutch in the power transmission system of the aseptic fillingapparatus is disconnected to stop rotation of only the wheel 9 of thecontent filling station 6, thereby stopping rotation of the fillingnozzles 32. In addition, the surge tank 33 is emptied.

(3) As shown in the right half of FIG. 3 , the nozzle mouth 32 a of thefilling nozzle 32 is closed by the cup 42. In addition, the coupling 44is connected. In this way, a circulation path for flowing apredetermined working fluid for the SIP (Step S1) such as a cleaningliquid or sterilizing liquid is formed.

(4) The SIP (Step S1) is started, and a predetermined working fluid suchas an alkali cleaning liquid or water is fed from the reservoir tank 38by the pump 39 in a predetermined order. The cleaning liquid or the likeflows through the feed pipe 40 from the reservoir tank 38 to the surgetank 33, passes through the drink supply piping 34, flows into the uppermanifold 37 and then to each filling nozzle 32, and eventually returnsto the reservoir tank 38 through the return pipe 41. Thus, the cleaningliquid or the like flows in the circulation path for a predeterminedtime in a predetermined order to clean the interior of the drink supplypiping 34 including the interior of the filling nozzles 32.

As shown in FIG. 15 , the SIP (Step S1) is performed by first supplyingan alkali cleaning liquid and flowing water in a final stage. Theseworking fluids flow in the circulation path at a temperature of 80° C.to 95° C., for example, and is discharged from the circulation pathafter a lapse of 10 to 30 minutes, for example. In this way, anyremaining cleaning liquid or waste liquid is removed from the drinksupply piping 34, and the SIP (Step S1) is completed. The interior ofthe drink supply piping is sterilized and cleaned at the same time, andthis means that the conventional CIP is performed at the same time.Thus, as is obvious from comparison between FIGS. 15 and 12 , the idletime between the end of filling with a drink and the start of fillingwith another drink is reduced. However, the content to be sterilized ispreferably a drink packaged in the hot packing method, such as an acidicdrink having a pH lower than 4.6, mineral water, or green tea having abacteriostatic action.

Removal of the waste liquid or the like from the interior of the drinksupply piping 34 is achieved by collecting the waste liquid or the likein the reservoir tank 38 and then drawing the waste liquid from thereservoir tank 38, for example.

Conditions of the temperature of the hot water used in the SIP (Step S1)and the duration of the SIP (Step S1) are determined based on theconditions required for sterilization of the content of the product. Forexample, in the case of a product having a pH lower than 4, thetemperature is at least 60° C., and the duration is 10 minutes, in thecase of a product having a pH of 4.0 to 4.6, the temperature is 85° C.,and the duration is 30 minutes, and in the case of a product having a pHequal to or higher than 4.6, the temperature is 120° C., and theduration is equal to or longer than 4 minutes (typically, thetemperature is 130° C., and the duration is equal to or longer than 30minutes). In the case where the SIP (Step S1) requires a temperatureequal to or higher than 100° C., a vapor can also be used in addition tothe hot water.

(5) When the SIP (Step S1) of the drink supply piping 34 of the contentfilling station 6 is performed, the SOP or COP (Step S3) is performed inparallel therewith on (i) the outer surface of various kinds ofequipment in the container molding station 4 in the chamber 19, (ii) theouter surface of various kinds of equipment in the container sterilizingstation 5 in the chamber 20, (iii) the outer surface of various kinds ofequipment in the container sealing station 7 in the chamber 21, and (iv)the outer surface of various kinds of equipment in the chamber 56 forthe cap sterilizing station 53.

In this process, the wheel 9 of the content filling station 6 isstopped, while the equipment, such as the wheels 10, 12, 13, 17 and 18,in the container molding station 4, the container sterilizing station 5,the container sealing station 7 and the cap sterilizing station 53 arebeing driven.

The SOP or COP (Step S3) is different from the SOP or COP (Steps S2, S4,S5, S6) of the content filling station 6 and the other stations, and ahydrogen peroxide solution is blasted from the injection nozzles 57, 50,52 and 54 to the outer surface of the container molding station 4, thecontainer sterilizing station 5, the container sealing station 7 and thecap sterilizing station 53.

In this process, since the container molding station 4, the containersterilizing station 5, the container sealing station 7 and the capsterilizing station 53 are being driven, the hydrogen peroxide solutionas a working fluid spreads into every corner of the various kinds ofequipment thereof to improve the cleaning effect and the sterilizationeffect.

In the SOP or COP (Step S3) of the other stations such as the containermolding station 4, hydrogen peroxide may also be sprayed from theinjection nozzle 45 to the content filling station 6 at rest to performthe SOP or COP (Step S2) of the content filling station 6 in parallelwith the SIP (Step S1).

By spraying hydrogen peroxide at the same time as the SIP (Step S1), theouter surface of the filling nozzles 32, which have a complicated shape,can be efficiently sterilized. More specifically, even when thetemperature of the filling nozzles 32 is 130° C., if the interior of thechamber 21 is dry, it is difficult to sterilize heat-resistantspore-forming bacteria because the sterilization is dry heatsterilization. However, as is obvious from FIG. 10 , which shows aresult of an experiment by the inventors, the outer surface of thefilling valves can be easily sterilized, provided that the concentrationof the hydrogen peroxide gas in the chamber 21 is equal to or higherthan 5 mg/L, and the temperature of the filling valves is equal to orhigher than 60° C.

When the SOP or COP (Step S3) is performed, the temperature of theatmosphere in the chamber 20 is raised by the aseptic hot air blastedinto the chamber 21 described above. As a result, the hydrogen peroxideis activated, the sterilization effect of the SOP or COP (Step S3) isimproved, and any excessive hydrogen peroxide solution is dried andremoved by the aseptic hot air after spraying of the hydrogen peroxidesolution.

(7) When the SIP (Step S1) of the interior of the drink supply piping 34in the content filling station 6 is completed, and the coupling 44 isdisconnected, the clutch described above is connected, so that the wheel9 is allowed to rotate in association with the other wheels 13, 17 andthe like. Alternatively, the wheel 9 is allowed to rotate by beingdriven by the dedicated servo motor for the wheel 9.

When the wheel 9 or the like starts rotating, the same SOP or COP (StepsS2, S4, S5, S6) is performed stepwise on the content filling station 6,the container sterilizing station 5, the container sealing station 7,the cap sterilizing station 53 and the container molding station 4.Steps S2, S4, S5 and S6 can be performed in any order.

(8) Supposing that Step S2 is first performed, a peracetic acid solutionis sprayed from the injection nozzles 54 to the content filling station6 during spraying of the aseptic water in Step S2.

When Step S2 is started, the wheel 9 of the content filling station 6starts rotating along with the other wheels, and thus the fillingnozzles 32 also start rotating.

Once Step S2 is performed on the content filling station 6, apredetermined working fluid such as a liquid chemical agent or asepticwater is sprayed from the injection nozzles 45 to the exterior of thecontent filling station 6 in a predetermined order. Since the workingfluid is blasted to the rotating filling nozzles 32 and the like, theouter surface of the filling nozzles 32 and the like is efficientlycleaned and sterilized.

The SOP or COP of Step S2 may be a process of deactivating bacteria byusing warm water or the like of a temperature equal to or higher than60° C. and lower than 100° C. instead of the sterilizer.

According to the sixth embodiment, in Step S2, the peracetic acidsolution as a sterilizer is first blasted from the injection nozzles 45to the content filling station 6 to sterilize the outer surface of thecontent filling station 6, and aseptic water is then blasted to wash anyexcessive peracetic acid as a sterilizer or dirt from the surface of thecontent filling station 6.

(9) Supposing that Steps S4 to S6 are then successively performed,injection of the peracetic acid solution in Steps S4 to S6 is performedstepwise at predetermined time intervals after the start of theinjection of the peracetic acid solution in Step S2. This ensures thatan appropriate amount of peracetic acid is blasted without shortage ofsupply thereof to each of the content filling station 6, the containersterilizing station 5, the container sealing station 7 and the capsterilizing station 53.

(10) Once the injection of the hydrogen peroxide solution in Steps S2,S4, S5 and S6 is completed, aseptic water is then successively blastedin steps S2, S4, S5 and S6 to the content filling station 6, thecontainer sealing station 7, the container sterilizing station 5, andthe cap sterilizing station 53. This ensures that an appropriate amountof aseptic water is supplied without shortage of supply thereof to eachof the content filling station 6, the container sterilizing station 5,the container sealing station 7 and the cap sterilizing station 53.

(11) In this way, the aseptic filling apparatus is decontaminated byperforming the SIP (Step S1) and the SOP or COP (Steps S2, S3, S4, S5,S6) of the parts of the aseptic filling apparatus where contamination isparticularly unwanted.

In addition, the aseptic air continues being blasted into the chamber 21to keep the surroundings of the content filling station 7 at a positivepressure. The aseptic air further flows to the container molding station4, the container sterilizing station 5 and the container sealing station7. Thus, the aseptic condition in the chambers 19, 20 and 21 ismaintained.

For the cap sterilizing station 53, the aseptic condition of theatmosphere in the chamber 56 is maintained by blasting aseptic air intothe chamber 56 from another system.

As shown in FIG. 14 , the time required to decontaminate the asepticfilling apparatus by the SIP (Step S1) and the SOP or COP (Steps S2, S3,S4, S5, S6) described in (1) to (10) above is about four hours. The timerequired for decontamination of conventional aseptic filling apparatusesis about six hours as shown in FIG. 11 , and it can be seen that thedowntime is reduced according to the present invention.

(12) After the SIP (Step S1) and the SOP or COP (Steps S2, S3, S4, S5,S6) described above are completed, manufacture of another kind ofbottled drink is started.

The method of manufacturing another kind of bottled drink is the same asthose according to the embodiments described earlier, and detaileddescriptions thereof will be omitted.

Seventh Embodiment

As shown in FIG. 16 , according to a seventh embodiment, the SIP (StepS1) and the SOP or COP (Step S3) achieved by spraying a hydrogenperoxide solution are performed as in the sixth embodiment, the SOP orCOP (Steps S2, S4, S5, S6) achieved by blasting a peracetic acidsolution and aseptic water is also performed stepwise on the contentfilling station 6, the container sealing station 7, the containersterilizing station 5 and the cap sterilizing station 53.

However, steps S2, S4, S5 and S6 are different from those in the sixthembodiment in the following points.

That is, as shown in FIG. 16 , a peracetic acid solution is firstblasted stepwise from the injection nozzles 45, 52, 50 and 54 to thecontent filling station 6, the container sealing station 7, thecontainer sterilizing station 5 and the cap sterilizing station 53 tosterilize the outer surface of the stations 7, 5 and 53, and asepticwater is then blasted stepwise to the stations 7, 5 and 53 to wash theremainder of the drink in the previous filling or any excessive hydrogenperoxide solution from the surface of the stations. In this process,cleaning with aseptic water in each preceding SOP or COP and cleaningwith peracetic acid in the subsequent SOP or COP are performed in atemporally overlapped manner. This ensures that peracetic acid suppliedin each SOP or COP is prevented from adhering to a part where peraceticacid supplied in the preceding SOP or COP is being washed and removed.

As described above, the SOP or COP (Steps S2, S4, S5, S6) of the contentfilling station 6, the container sterilizing station 5, the containersealing station 7 and the cap sterilizing station 53 is performedstepwise in such a manner that cleaning with aseptic water and cleaningwith peracetic acid are performed in an overlapped manner, so that thedowntime of the aseptic filling apparatus is further reduced, and theproductivity of the bottled drink is further improved.

Eighth Embodiment

As shown in FIG. 17 , according to an eighth embodiment, although theSIP (Step S1) and the SOP or COP (Step S3) achieved by spraying ahydrogen peroxide solution are performed as in the sixth embodiment, theSOP or COP (Steps S2, S4, S5, S6) achieved by blasting a peracetic acidsolution and aseptic water is simultaneously performed on the contentfilling station 6, the container sealing station 7, the containersterilizing station 5 and the cap sterilizing station 53.

Since the SOP or COP (Steps S4, S5, S6) of the container sterilizingstation 5, the container sealing station 7 and the cap sterilizingstation 53 is performed in parallel with the SOP or COP (Step S2) of thecontent filling station 6 in this way, the downtime of the asepticfilling apparatus is further reduced, and the productivity of thebottled drink is further improved.

In addition, when the SIP (Step S1) of the content filling station 6 isperformed, the SOP or COP (Step S3) using hydrogen peroxide of the otherstations such as the container sealing station 7 is performed inparallel therewith. In this process, the wheels 17 and the like of theother stations such as the container sealing station 7 are rotating, sothat the sterilization effect of the other stations such as thecontainer sealing station 7 is improved.

Although the present invention is configured as described above, thepresent invention is not limited to the embodiments described above, andvarious modifications can be made without departing from the spirit ofthe present invention. For example, Steps S5, S6 and 27 may be performedat the same time as Step S3. Furthermore, the container is not limitedto a bottle but may be a paper container. The content is not limited toa drink but may be a liquid food, for example.

Furthermore, in FIGS. 7, 9 and 10 , for example, cleaning andsterilization (S5, S6, S7) of the chambers other than that for thecontent filling station may be performed at the same timing as the CIP(S1) or SIP (S2) of the content filling station.

Furthermore, in FIGS. 14, 16 and 17 , for example, cleaning andsterilization (S4, S5, S6) of the chambers other than that for thecontent filling station may be performed at the same timing as the SIPor CIP (S1) of the content filling station.

Furthermore, the container is not limited to a bottle but may be a papercontainer. The content is not limited to a drink but may be a liquidfood, for example.

The method of sterilizing the container (bottle and cap) may be chemicalagent rinse sterilization with peracetic acid or the like orelectron-beam sterilization, rather than sterilization with hydrogenperoxide. The preform may be sterilized instead of sterilizing thebottle.

REFERENCE SIGNS LIST

-   3 container (bottle)-   5 container sterilizing station-   6 content filling station-   7 container sealing station-   9, 12, 13, 17 wheel-   20, 21, 56 chamber-   32 filling nozzle-   51 lid (cap)-   53 lid sterilizing station (cap sterilizing station)

The invention claimed is:
 1. A method of decontaminating an asepticfilling apparatus, the aseptic filling apparatus comprising variouskinds of stations including a content filling station arranged from anupstream side to a downstream side of a flow of a preform or containerfed by rotation of wheels in a wheel train, and each of the variouskinds of stations being covered by a chamber, wherein a CIP of thecontent filling station is performed after rotation of a wheel in thecontent filling station is stopped, the temperature of a cleaning liquidis raised to a temperature required for an SIP subsequent to the CIPfrom an early stage or a middle of the CIP, the SIP of the contentfilling station is performed to sterilize the content filling stationand the cleaning liquid is removed with rotation of the wheel in thecontent filling station kept stopped, and one or both of a COP and anSOP of the content filling station is performed in a predetermined orderwhile the wheel in the content filling station is rotating immediatelyafter the SIP is completed.
 2. The method of decontaminating an asepticfilling apparatus according to claim 1, wherein the SOP of the contentfilling station and the SOP of other stations are performed stepwiseimmediately after the SIP of the content filling station is completed.3. The method of decontaminating an aseptic filling apparatus accordingto claim 2, wherein the SOP is performed by blasting of hot water or asterilizer and blasting of aseptic water.
 4. The method ofdecontaminating an aseptic filling apparatus according to claim 1,wherein the SOP of the content filling station and the SOP of otherstations are performed in parallel with each other immediately after theSIP of the content filling station is completed.
 5. The method ofdecontaminating an aseptic filling apparatus according to claim 1,wherein the SOP of other stations is performed while the CIP or SIP ofthe content filling station is being performed, and the SOP is performedby spraying of a sterilizer containing hydrogen peroxide or blasting ofgas or mist of the sterilizer.
 6. The method of decontaminating anaseptic filling apparatus according to claim 1, wherein aseptic air isconstantly blasted to the content filling station in the chamber.
 7. Themethod of decontaminating an aseptic filling apparatus according toclaim 1, wherein a clutch that connects and disconnects transmission ofpower between wheels is provided between the wheel in the contentfilling station and a wheel in another station, and the clutch isdisconnected to stop rotation of the wheel in the content fillingstation.
 8. The method of decontaminating an aseptic filling apparatusaccording to claim 1, wherein the wheels in the wheel train are capableof being rotated independently of each other by a dedicated servo motor,and the dedicated servo motor is stopped to stop rotation of the wheelin the content filling station.
 9. The method of decontaminating anaseptic filling apparatus according to claim 1, wherein, of the variouskinds of stations, the stations other than the content filling stationinclude at least one selected from a container molding station, acontainer sterilizing station, a container sealing station and a lidsterilizing station.